Compound structural frame with integrally formed thermal cooling channels and method of using same

ABSTRACT

A support for plural display modules each including a rearwardly extending heat sink includes a compound structural frame that defines a frame frontside, a frame backside, and a vertical cooling conduit, the frame backside for mounting the structural frame to a mounting structure, the frame frontside defining a bay member, the bay member defining an opening that couples to the vertical cooling conduit, the bay member configured to receive and support one of the display modules with the heat sink extending through the opening and into the vertical cooling conduit whereby the display module is convectively cooled by the vertical motion of air through the cooling conduit.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/844,832, entitled “Billboard Into a Dynamic ElectronicBillboard, and Methods of Retrofitting and Using Same”, by DavidFranklin Cox, et al., Filed on Mar. 16, 2013.

FIELD OF THE INVENTION

This invention relates generally to roadside and building signage, andmore particularly to a retrofit kit for in field use to convert a staticbillboard into a dynamic electronic sign for roadside or buildingsignage use.

BACKGROUND OF THE INVENTION

Retrofitting non-digital billboards have proven to be expensive, timeconsuming and labor intensive. Moreover, simply removing an oldernon-digital billboard and replacing it with a new digital billboard hasnot proven entirely satisfactory since older installed, non-digital,billboard panels represent substantial capital outlays making itfinancially difficult, if not impossible, to discard such panelsarbitrarily for replacement with digital panels. Therefore, it would behighly desirable to have a new and improved billboard retrofit kit thatcan be easily and quickly installed on an existing billboard, withoutthe need to replace or discard existing non-digital panels. The new andimproved billboard retrofit kit should greatly improve displayedinformation, displaying such advertising information, with improvedresolution, contrast and brightness characteristics. Moreover, theretrofit kit should enable the displayed content to be easily andquickly changed or updated, either on-site or remotely, at a lesser costthan updating the content of an older non-digital billboard. Finally,installation of the kit in the field on an existing billboard structureshould not require any special installation equipment and should be ableto be accomplished by one or two individuals in a fast and convenientmanner.

SUMMARY OF THE INVENTION

Throughout this specification the word “comprising”, or variations suchas “comprise”, or “comprises”, will be understood to imply the inclusionof a stated element, integer or step, or group of elements, integers orsteps, but not the exclusion of any other element, integer or step, orgroup of elements, integers, or steps.

In a first aspect, the present invention is a support for plural displaymodules, comprising: a compound structural frame having a back surface,a front surface, and plural peripheral edges coupling said back surfaceand said front surface for defining a plurality of structural baymembers for receiving and supporting therein corresponding individualones of the plural display modules; wherein each individual one of saidplurality of structural bay members is provided with a front surfaceopening feature extending into back surface vertical channel, said backsurface vertical channel defining an airflow path extending from abottom surface area of said compound structural frame to a top surfacearea of said compound structural frame; and wherein each individual oneof the plural display modules is provided with a set of cooling finsdimensioned to be supported within said front surface opening featureand extending therethrough into said back surface vertical channel tofacilitate display module cooling purposes.

In one embodiment, the plurality of structural bay members are arrangedin rows and columns, the rows and columns being defined by a pluralityof front face surface lateral ribs and at least one front face surfacelongitudinal rib; and wherein the plurality of front face surfacelateral ribs and the at least one front face surface longitudinal ribdefine a plurality of cutting line guides to help facilitate cutting thecompound structural frame into one or more individual structural baymembers to provide a customized support ranging in size from a startingmaximum full frame size for supporting and receiving the plural displaymodules to a minimum structural bay member size for supporting andreceiving an individual one of the plural display modules.

In another embodiment, the front surface is provided with a plurality ofdisplay module mounting features to facilitate mechanically andelectrically coupling the plural display modules in the plurality ofstructural bay members.

In a still further embodiment, each individual one of the plurality ofstructural bay members has a sufficient number of cutout areas toprovide a frame weight of no greater than 50 pounds for hand lifting andmounting to the front-face surface by a single person without the use oflifting equipment, but not such a sufficient number of cutout areas tocompromise the structural integrity of the compound structural frame forresisting wind load forces in excess of 100 pounds per square foot whenmounted to the front-face surface while supporting the plural display.

In yet another embodiment, the compound structural frame is composed ofstructural foam to help minimize frame weight for hand lifting andmounting of the compound structural frame by one person without the useof a mechanical frame lifting arrangement.

In still yet another embodiment, the airflow path defined by verticalchannel is a natural convective air flow path.

In a still further yet another embodiment, the airflow path defined bythe vertical channel is a forced convective air flow path.

In still yet another embodiment the compound structural frame isprovided with a plurality of mounting features to facilitate mountingthe compound structural frame to a mounting structure.

In still yet another embodiment, each individual one of the plurality ofstructural bay members is provided with a plurality of irregularlyshaped cut out areas.

In a still further yet another embodiment, the plurality of structuralbay members are equally spaced apart and sized for receiving andsupporting therein corresponding individual ones of the plural displaymodules.

In a second aspect, the present invention is a support for pluraldisplay modules, each having a rearwardly extending heat sink,comprising: a compound structural frame having a plurality of mountingfeatures to facilitate mounting the compound structural frame to amounting structure; wherein said compound structural frame defines aframe frontside and a frame backside with at least one vertical coolingchannel; wherein the frame frontside defines at least one structural baymember, the at least one structural bay member having an opening influid communication with the at least one vertical cooling channel; andwherein the opening is dimensioned to receive and support therein anindividual rearwardly extending heat sink to facilitate the heat sinkextending through the opening and into the at least one vertical coolingchannel for display module cooling purposes.

In one embodiment of the second aspect, each rearwardly extending heatsink includes a plurality of cooling fins that have a sufficient lengthto extend into the at least one vertical cooling channel.

In another embodiment of the second aspect, the at least one verticalchannel facilitates natural convective cooling with air motion movingfrom a bottom side of the compound structural frame to a top side of thecompound structural frame.

In a further embodiment of the second aspect, the frame backside isprovided with at least another vertical cooling channel.

In a still yet another embodiment of the second aspect, the at least onestructural bay member is dimensioned to latchingly receive therein anindividual one of the plural display modules.

In a further embodiment of the second aspect, the frame frontsidedefines at least another structural bay member; and wherein the at leastanother structural bay member is in fluid communication with the atleast another vertical cooling channel.

In another embodiment of the second aspect, at least one structural baymember and the another structural bay member are arranged in rows andcolumns, the rows and columns being defined by a plurality of front facesurface lateral ribs and at least one front face surface longitudinalrib; and wherein the plurality of front face surface lateral ribs andthe at least one front face surface longitudinal rib define a pluralityof cutting line guides to help facilitate cutting said compoundstructural frame into one or more individual structural bay members toprovide a customized support ranging in size from a starting maximumfull frame size for supporting and receiving the plural display modulesto a minimum structural bay member size for supporting and receiving anindividual one of the plural display modules.

In yet another embodiment of the second aspect, the at least onestructural bay member has a sufficient number of cutout areas to providea frame weight of no greater than 50 pounds for hand lifting andmounting to the mounting structure by a single person without the use oflifting equipment, but not such a sufficient number of cutout areas tocompromise the structural integrity of the compound structural frame forresisting wind load forces in excess of 100 pounds per square foot whenmounted to the mounting structure while supporting the plural display.

In still yet another embodiment of the second aspect, compoundstructural frame is composed of structural foam to help minimize frameweight for hand lifting and mounting of the compound structural frame byone person without the use of a mechanical frame lifting arrangement.

According to a third aspect, the present invention is a support forplural display modules each including a rearwardly extending heat sinkcomprising: a compound structural frame that defines a frame frontside,a frame backside, and a vertical cooling conduit, the frame backside formounting the structural frame to a mounting structure, the framefrontside defining a bay member, the bay member defining an opening thatcouples to the vertical cooling conduit, the bay member configured toreceive and support one of the display modules with the heat sinkextending through the opening and into the vertical cooling conduitwhereby the display module is convectively cooled by the vertical motionof air through the cooling conduit.

BRIEF DESCRIPTION OF DRAWINGS

The above mentioned features and steps of the invention and the mannerof attaining them will become apparent, and the invention itself will bebest understood by reference to the following description of theembodiments of the invention in conjunction with the accompanyingdrawings wherein:

FIG. 1 is a perspective view of a digital billboard constructed inaccordance with the present invention through the use of the in fieldmodification kit of FIG. 1;

FIG. 2 is a diagrammatic block diagram of a field modification kit forconverting a non electronic billboard sign into an electronic billboardsign, wherein the field modification kit is constructed in accordancewith the present invention;

FIG. 3 is a front plane view of a non electronic billboard sign beingprovided with chalk marks for a grid layout indicative of the size andpattern of the structural frames being installed on the existing posterpanels; modification kit is constructed in accordance with the presentinvention;

FIG. 4 is a greatly enlarged frontside perspective view of a structuralframe forming part of the field modification kit of FIG. 2;

FIG. 5 is a greatly enlarged frontside perspective view of the of thestructural frame forming part of the field modification kit of FIG. 2,illustrating some of the modular components forming part of the fieldmodification kit of FIG. 2;

FIG. 6 is a greatly enlarged backside perspective view of the structuralframe of FIG. 4;

FIG. 7 is a backside perspective view of the structural frame of FIG. 5illustrating some of the modular components forming part of the fieldretrofit kit of FIG. 2;

FIG. 8 is an enlarged frontside perspective view of a display moduleforming part of the field modification kit of FIG. 2;

FIG. 9 is an enlarged backside plane view of the display module of FIG.8:

FIG. 10 is an exploded view of the display module of FIG. 8;

FIG. 11 is an exploded view of a daughter board forming part of thedisplay module of FIG. 10;

FIG. 12 is a perspective view of a bee stop utilized to occlude a wiringaccess opening forming part of the structural frame of FIG. 5;

FIG. 13 is a greatly simplified electrical circuit block diagram of thedisplay module of FIG. 11;

FIG. 14 is a diagrammatic view illustrating a column number arrangementforming part of the power and data distribution system of the in fieldmodification kit of FIG. 1;

FIG. 15 is a flowchart illustrating the steps followed in installing thedisplay modules forming part of the field retrofit kit of FIG. 2;

FIG. 16 is a greatly enlarged front perspective view of a portion of alouver forming part of a display module constructed in accordance withthe present invention, illustrating a pixel arrangement of lightemitting diodes;

FIG. 17 is a schematic illustration of how all the power/data harnesses,all the data jumper cables and all the data connection cables are layoutin the frame array and routed to respective power access holes and dataaccess holes within the frame array leading to backside billboardjunction boxes.

FIG. 18 is a flowchart illustrating the steps followed in assembling alight emitting diode display module forming part of the in fieldmodification kit of FIG. 2;

FIG. 19 is a flowchart illustrating the steps followed in using the infield retrofit kit of FIG. 2 to convert a non electronic billboard intoan electronic billboard;

FIG. 20 is a flowchart of the steps followed by an installation team inpreparing an existing billboard for the retrofitting process;

FIG. 21 is a flowchart of the steps followed by an installation team inpreparing an existing billboard site for installation of the structuralframes;

FIG. 22 is a flowchart illustrating the steps followed by aninstallation team for installation of the power and data wire harnessesof FIG. 24C using the in field modification kit of FIG. 2, to convert astatic sign into a dynamic advertising display;

FIG. 23 is a front plane view of a structural frame forming part of theretrofit kit of FIG. 2;

FIGS. 24A, 24B and 24C are diagrammatic illustrations of various harnessassemblies forming part of the power data routing system;

FIG. 25 is a front elevational view of the billboard of FIG. 1, with itsdisplay module louvers removed to illustrate the side by siderelationship of the individual display panels forming part of thedisplay module of FIG. 8;

FIG. 26 is a rear elevational view of a billboard of FIG. 1,illustrating component parts of the power data routing system;

FIG. 27 is a front plane view of an array of structural framesillustrating their preparation for installation of the power wireharnesses and data wire harnesses of FIG. 24C;

FIG. 27A is a top plane view of the structural frame of FIG. 23illustrating typical locations far bee stops and air flow channels;

FIG. 28 is a diagrammatic illustration of how the data/power harnesswith over mold nodes are laid out and secured to a structural frame ofthe present invention;

FIG. 29 is a greatly enlarged perspective view of a chimney vent coverforming part of the field modification kit of FIG. 2;

FIG. 30 is a greatly enlarged perspective view of a frame latch assemblyforming part of the field modification kit of FIG. 2;

FIG. 31 is a top plane view of the frontside of a printed circuit boardforming part of the display module of FIG. 8;

FIG. 32 is a top plane view of the backside of a LED frame forming partof the display module of FIG. 8;

FIG. 33 is a top plane view of the frontside of the LED frame of FIG.32; and

FIG. 34 is a perspective view of the LED frame of FIG. 32, illustratinga seating wall adapted to be seated in a structural frame bay member.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

For reference purposes, whenever the term “frontside” is used it willalways refer to the front viewing side of any element or component partthat will be described hereinafter. Backside always opposes thefrontside for any part or portion being discussed and is the reverse ofthe viewing side. Each surface is defined hereinafter in the followingmanner as a part frontside/backside.

Referring now to the drawings and more particularly to FIGS. 1 and 2,there is illustrated a self contained retrofit kit 10 and a resultingdynamic electronic sign or billboard 110 respectively, which kit 10 andwhich billboard 110 are each constructed in accordance with the presentinvention. The electronic billboard 110, when constructed in accordancewith a novel method of retrofitting or assembling 1010 (FIG. 19) ashereinafter disclosed, is assembled in a fast and convenient mannerwithout the need of special tools or equipment. In short, by use of thein field retrofit kit 10, a static non-electronic billboard 8, as bestseen in FIG. 3, is transformed or converted into a dynamic electronicbillboard 110 that greatly improves displayed information, such asadvertising information, with improved resolution, contrast, andbrightness characteristics. The simplicity of the various hand mountablecomponent parts of the electronic billboard 110 are such, that a team oftwo people or even a single installer, with a ladder, a drill, a skillsaw, a hammer and a screwdriver are able to quickly and easily convertan existing static (non electronic) roadside or building billboard 8into a high-tech digital billboard 110. As an example, the simplicity ofthe design enables a digital billboard 110 constructed in accordancewith the present invention, to be utilized in a football stadium duringthe football season, and then if desired, disassembled and moved to abaseball stadium and re-assembled for billboard display presentationsduring the baseball season. Portability and easy of assembly anddisassembly are unique and important novel features of the presentinvention.

For the purpose of this disclosure the term static non-electronicbillboard or sign with respect to being retrofit by the retrofit kit 10,means any sign that has an advertising display mounting surface composedof steel, wood, concrete, masonry or other suitable mounting materialsof a sufficient strength to support the array of structural framesprovided in the retrofit kit 10. The advertising media of such a staticnon-electronic billboard or sign includes paper, paper panels and anyother advertising media having permanent and non-changing indicia in theform of images, text, and symbols disposed thereon. Notwithstanding theforegoing, it is contemplated that the billboard 110 of the presentinvention may also be utilized to replace existing electronic signage,whether such electronic signage is of a roadside structure or an indooror outdoor building structure configuration.

As will be explained hereinafter in greater detail, the electronicbillboard 110 is constructed by the use of standardized ultralightweight hand mountable structural frames composed of structural foamand fully integrated electronics for simple and quick, “plug and play”installation. The panelized or sectional construction of the billboard110 as described herein allows for installation with no major structuremodifications being required at the sign installation site. Existingalternating current power, for operation in the United States, such as a2-phase, 40 amp, 240 VAC source or a 2-phase, 80 amp, 120 VAC source,supplied for illuminating the non electronic billboard 8 is all that isrequired for the fully integrated electronics forming part of thebillboard 110. Power converters, as optional equipment, may be providedso the conversion process may utilize “universal power” as providedanywhere in the world for driving the fully integrated electronicsforming part of the billboard 110 as will be explained hereinafter ingreater detail.

The modular nature of the billboard 110 and the hand mountable componentparts of the in field modification kit 10 allow for installation in afast and convenient manner. The frame construction utilizing by the kit10, coupled with “plug and play” electronic technology allows for acustomer to retrofit virtually any existing non electronic billboard 8into a sophisticated electronic billboard 110 capable of displayinginstantaneously changing images and textual information for achievingsignificantly improved advertising results than previously provided forby the static billboard 8.

In summary then, the in field modification kit 10 when used inaccordance with the method of retrofitting 1010 facilitates theconversion of a static non electronic billboard 8 into a dynamicelectronic billboard display 110, which obtains for a customer severalunique and novel advantages:

1. The in field modification kit 10 enables a static billboard display 8to be easily and quickly converted into a dynamic billboard 110, wheredisplayed information can be changed instantaneously and remotely asneeded via a power data routing system that will be describedhereinafter in greater detail;

2. The simplicity of the kit design allows for the installation by aninstallation team or even a single installer without sophisticatedinstallation training;

3. The converted electronic billboard 110 is relatively inexpensive tooperate using low power consumption electronic devices;

4. The integration of the existing on-site power utilized to illuminatea static billboard coupled with the use of standardized modularcomponents with integrated preformed power and data cables allows forquick and easy installation;

5. The utilization of a structural frame construction that duplicatesitself coupled with the utilization of a display module constructionwhich also duplicates itself completely eliminates the common need ofsection identification markers normally required of sectional signs,such as the sectional sign of the present invention;

6. The utilization of a ultra-light frame construction permits theretrofit kit of the present invention to be easily and convenientlytransported to any remote sign location for installation by hand withoutthe need of any special moving equipment; and

7. The simplicity of the dynamic billboard design allows for the use ofexisting poster panels in an existing static billboard making theretrofit process highly efficient.

The Retrofit Kit

Before describing in detail the on-site or in-field retrofitting process1010, it will be beneficial to first describe the retrofit kit 10 thatis utilized by an installation team or installer in transforming thestatic billboard 8 into the dynamic billboard 110. In this regard, theretrofit kit 10 as best seen in FIG. 2, generally includes (1) aplurality 10A of thin, ultra-light weight compound functional structuralframes, such as a compound structural frame 12 as best seen in FIG. 23;(2) a plurality 10B of fully weatherized latch in place display modules,such as a display module 14, as best seen in FIGS. 8-9; (3) a plurality10D of preformed wire harness assemblies as best seen in FIGS. 24A-C;and (4) a power modification kit 10C that enables the plurality 10D ofharness assemblies to be coupled to a source of electrical informationor data as well as a source of universal power that will be describedhereinafter in greater detail. The kit 10 also includes an instructionmanual and mounting hardware 10F, as well as an insect and rodentinfestation resistance kit 10E that will also be described hereinafterin greater detail.

The Structural Frames and Display Modules of the Kit, in General

As best seen in FIG. 23, each structural frame 12 forming part of theretrofit kit 10 includes a plurality of structural bay members, such asa structural bay member 16 as best seen in FIGS. 4-7. FIG. 23 is a frontplane view of a single structural frame 12 having an array of structuralbay members 16 arranged in a five (5) bay high by a two (2) bay wideconfiguration. FIGS. 4-5 are greatly enlarged frontside views of anindividual structural bay member 16 without and with certain installedfeatures respectively. FIGS. 6-7 are greatly enlarged backside views ofan individual structural bay member 16, also illustrated with andwithout certain installed features respectively. Each structural baymember 16 is adapted to receive and support therein a fully weatherizedand sealed LED display module 14. The display module 14 of the presentinvention may be installed in any structural bay member 16 forming partof the electronic billboard 110. In this regard, the display module 14of the present invention is universal, and requires no special sectionalmarkings or indicia for installation purposes.

As will be explained hereinafter in greater detail, the structuralframes 12 and its associated structural bay members 16 have built inalignment features, self cooling features, wire routing features, andnode receptacle feature, which (1) facilitate a quick and easyinstallation process for the fully weatherized LED display modules 14;(2) facilitate and provide front billboard access for simple servicingprocesses which easy removal and replacement of display modules 14 asneeded; (3) facilitate simple and effective cooling methods for eachdisplay module 14 due to a unique and novel structural cooperationbetween the structural frames 12 and the existing static billboardposter panels, such as a poster panel 9; and (4) facilitates a uniqueand novel overall billboard structure that substantially preventsinvasion by bees and other insects or pests into the hollow interiorareas of the billboard 110.

Each individual display panel module 14 which forms part of the kit 10and the billboard 110 includes dual LED display panels indicatedgenerally at 14L and 14R as best seen in FIGS. 8-9. This dual LEDdisplay panel construction of the display module 14 provides for thedisplay of a total of 512 multi-color pixels (red, green and blue)consisting of 1536 LEDs (512R/512G/512B) which LEDs are configured inidentical pixel arrangements, such as a pixel arrangement 18 as bestseen in FIG. 16. Each LED display module 14 as best seen in FIG. 8, is317 mm in height or about one foot in height and 634 mm in width orabout two feet in width, so arrangement that two display board with 512pixels are distributed over 0.2 square meters or about 2.16 square foot.Each pixel in this regard, includes a red LED, a green LED, and a blueLED to provide thousand of pixel color combinations. Each pixelarrangement 18 is therefore configured with a pixel pitch given by thefollowing formula:Pixel pitch=317 mm÷16=19.8 mm  [Equation 1]Accordingly, each pixel arrangement 18 is configured as a 19.8millimeter display arrangement with a narrow viewing angle, which isbest suited to roadside billboard products, optimized sign brightnessand hence configured for the utilization of less power. It should benoted that wider angle light emitting diodes are fully contemplated foruse without changing the other physical components of the presentinvention to accommodate various types of advertising displays such ashigh definition video displays for indoor use as an example withoutlimitation.

The total number of compound structural frames 12 and the total numberof display modules 14 provided in any given retrofit kit 10 isdetermined in advance by the size of the static billboard 8 that isbeing converted. Table I that follows provides a cross reference betweenstandard sized billboards and the number of compound frames 12 anddisplay modules 14 provided in any given kit:

TABLE I Standard Billboard Size Number of Frames Number of Modules 11Ft. (Height) 10 Full Size Frames 100 Modules by 22 Ft. (Width) 14 Ft.(Height) 22 Full Size Frames 230 Modules (Lower 2 Rows) by 48 Ft.(Width) and 11 Partial Frames  69 Modules (Upper Rows) with top pair ofbays removed, and 3 Partial Frame with one column of bays removed

Each structural frame 12 in the retrofit kit 10 is composed of a lowcost, light weight structural foam material which easily andconveniently mates in a tight surface to surface configuration with theposter panel surfaces of the existing static billboard 8. Such matingprovides a low cost means to support routed wires and to cool thedisplay modules, such as the display module 14 by and through unique andnovel design flexibility, light weight properties, strength andweathering capabilities. As needed for certain standard size staticbillboards, a structural frame 12 may be easily and quickly configuredinto smaller units by the simple use of a skill saw.

The surface mating properties between the closed poster panel surfacesof the static billboard 8 and the individual structural frames 12 whichare sealed by the individual weatherized display modules 14, furthereliminates the need for air conditioning and or fans to cool the largenumber of display modules 14 distributed across a frame array 30 of thebillboard 110. In this regard, a passive cooling structure or ventingsystem is formed in this surface to surface mating relationship whichallows substantially portions of the display module 14 to be latched andfixedly removably positioned or located within individual ventingchannels (FIG. 27) designed into the physical configuration ofindividual ones of the compound structural frames 12.

It should be appreciated by those skilled in the art, that the surfacemating properties enable the individual structural frames 12 to furtherfunction as effective cable trays, wire harnesses, and conduits for thepower and data cables coupled to the various ones of the displaymodules. Moreover, the sealed display modules 14, as will be describedhereinafter in greater detail, eliminate the need for any type ofsealing between the modules 14 and their receiving bay members, such asthe bay member 16. This in turn, provides an added benefit namely thatlittle or no static billboard steelwork modifications are required. Alsowith the aid of an interconnecting daughter board 20, as best seen inFIGS. 7 and 10, a significant reduction is achieved as only a singleDC/DC converter is utilized to power the two optimum sized LED panels14L and 14R respectively of the display module 14. In short, thesimplicity of the in field retrofit kit 10 enables a “Digital Sign in aBox” kit type of methodology, which moves assembly of the dynamicbillboard 110, from the factory to a field end user. This is especiallyattractive for hard to reach or landlocked sites where cranes cannotgain access.

It should be further appreciated by those skilled in the art, that thestructural foam material that each structural frame 12 is constructed ofis not subject to post shrinkage and therefore the structural integrityof a resulting billboard 110, is protected and weatherized against postextreme cold and extreme heat experiences in normal weather conditions.Moreover, mounting or latching tolerances required of the latched indisplay modules will not be affected so there is no danger of a displaymodule 14 or any other component of the sign 110 from distorting due toshrinkage. In this regard, safe and effective operation of the dynamicbillboard sign 110 can be expected over a substantial life period ofabout 10-15 years or longer.

Based on the foregoing, it should be understood by those skilled in theart, that the retrofit kit 10 is a self contained, in-field or on-site,retrofit kit 10 for converting a static billboard 8 having a least oneposter panel 9 into a dynamic electronic billboard 110 which is adaptedto be coupled to a universal source of electrical power. To effect theconversion from a static billboard 8 to a dynamic billboard 110, the kit10 may be customized for the size of the static billboard 8 beingconverted. In this regard, there is no intention of limiting the size ofthe kit 10 to the precise size described herein as it is fullycontemplated that larger and smaller kit size may be constructed, forexample a kit with at least one modular compound structural frame 14that is adapted to be mounted to at least one poster panel 9 of thestatic billboard 8.

The number of modular compound structural frames 12 provided in anygiven kit 10, as noted earlier, is therefore determined by the actualsize of the static billboard 8. In this regard, a static billboard canbe as small as about a 2 square foot billboard or as large as needed. Inthis regard, the kit is fully scalable by adding additional powerenclosures and power junction boxes as needed.

Another unique and novel feature of the structural frame 12 as alreadybriefly mentioned is that when a structural frame 12 is mounted to theposter panel structures of the static billboard 8, the backside of thestructural frame 12 cooperates with the frontside of the poster panels,such as the poster panel 9, to form a pair of air columns or selfcooling air vents 91 as best seen in FIGS. 23 and 27A. The air ventcolumns 91 extend from the bottom of the structural frame 12 to the topof the structural frame 12. Still yet another unique and novel featureof the structural frame 12 is that the structural frame 12 furtherfunctions to define a plurality of wire routing paths, node receptacles,and frame/poster panel access paths which are disposed throughout thebillboard 110. These access paths, as will be described hereinafter,ensure that all the HVAC power is confined to the backside of thebillboard 110, while all the LVDC power is coupled to the frontside ofthe billboard 110; thus, making the billboard 110 very safe frompotential electrical shock scenarios.

The air vents or air conduits 91 formed between each structural frame 12and its associated poster panels 9 are formed due to the physicalstructure of the structural frame 12 as it is secured to the flatsurface area of the poster panel 9 on billboard 8. In this regard, acooling vent 91 is disposed in a left side column of the structural baymembers or in a right side column of structural bay members relative toa structural frame 12. In this regard, since the structural bay membersare arranged in 5 separate rows and two separate columns, the structuralframe 12 may be customized in size to provide a single cooling ventcolumn 91 or a pair of spaced apart cooling vent columns 91 as needed.

This passive cooling arrangement is an important and novel feature ofthe present invention. In this regard, when there is a large array ofLED modules provided in a large outdoor billboard display, there may betemperature variations across the display array. In particular, modulesthat are disposed toward the center of the display array or toward thehigher points in the array, may reach higher temperature during normaloperating conditions. It is for this reason that conventional billboarddisplay systems are provided with active fan driven cooling arrangementto compensate for these variations. The present invention however solvesthe variation in heat spots in a unique and novel way with a passivecooling system that uses the cooperation of air channels 91 (FIGS. 23and 27A) built into the backside of each structural frame 12 to providea plurality of cooling conduits spread out across the whole of thestructural frame array 30. Moreover, windows or cutout areas, such as adaughter board window 330 (FIGS. 5-6) forming part of each structuralbay member 16 enable a set heat sink cooling fins, indicated generallyat 24F (FIG. 11) associated with each display module 14, to be locatedwithin an associated cooling vent 91 where air flow travels from abottom area of the billboard 110 to a top area of the billboard 110 bynatural air flow convection. With this natural air column structure,should a billboard 110 be constructed from a retrofit kit 10 andinstalled in an extremely hot and humid environmental area of thecountry, cooling fans could be quickly and easily installed for eachcooling vent 91 to provide forced convection cooling along these coolingvent paths, if needed.

Yet another unique and novel feature of the compound structural frame 12is its compound structure. That is, a single structural frame 12contains plural structural bay members, such as the structural baymember 16. Each bay member 16 is adapted to latchingly receive andsecure one completely weatherized display module 14, which in turn, asalready mentioned is configured with side by side LED boards or panels,such as the left side display panel 14L and the right side display panel14R. The bay member 16 and the display module 14 of the retrofit kit 10are provided with complementary alignment and latching features thatwill be described hereinafter in greater detail. It will suffice for themoment to mention that each display module 14 includes a set of rearside alignment receptacles, such as a rear side alignment receptacle14AR, as well as a pair of spaced apart center alignment receptacles14CAR as best seen in FIG. 9, which receptacles 14AR and 14CAR areadapted to slidably receive therein a corresponding set of structuralbay alignment posts or columns, such as upstanding alignment posts 60ARand 60ARC respectively (FIGS. 4-5). In this regard, each display module14 is slidably mounted into a structural bay 16 from the frontside ofthe billboard 110 for easy and quick installation.

As mentioned earlier, the display module 14 of the present invention islatched into placement within an associated structural bay member 16. Inthis regard, each display module 14 also includes a set of latchreceiving members, such as a latch receiving member 14LM (FIG. 9), whichlatch receiving member 14LM is adapted to receive a latch member 416(FIG. 5) from an associated latch assembly 412, which assembly 412 ismounted within the structural bay member 16. This latching arrangementis an important and novel feature of the present invention, as it notonly allows for the individual ones of the display modules to be easilyand quickly installed or removed from an associate, structural baymember 16, but it also protect each display module 14 from beingdislodged from its associate bay member 16 due to unwanted andunexpected wind load forces.

It should be noted that each display module 14 is latched into place bya simple quarter turn with a latch access tool (not shown) such as aconventional Allen wrench tool. It should further be noted that when adisplay module 14 is mounted within an associated structural bay members16, it is mounted in abutment with another display module 14. In thisregard, a continuous line of display modules is configured on thefrontside of the billboard 110 as best seen in FIG. 25 to provide anuninterrupted side by side relationship and an uninterrupted top tobottom relationship. The abutment of the weatherized display modules, ina tight fit with one another, is therefore by design and effectivelyseals the frontside of the structural bay members of each structuralframe within the array 30, while at the same time forming asubstantially flat frontside face construction for the billboard 110,which substantially flat front face construction is extremely resistantto wind load forces.

As above-described, each display module 14 is latched in place by alatch assembly 412 which is disposed to the backside of the displaymodule 14 creating a latch assembly access issue. This access problemfor removing a display module 14 from its associated bay member 16 fromthe frontside of the billboard 110 was solved by providing each displaymodule 14 with a set of latch access holes, such as a latch accessaperture 17H as best seen in FIG. 9. In this regard, the access aperture17H enable an installer to use his or her tool and reach a sufficientdistance through the display module 14 to activate each associated latchwith a simple quarter turn, thus securing the display module 14 withinits structural bay member 16.

The display module 14 is further adapted to be coupled to a universalsource of electrical power via an individual one of the plurality ofwire routing paths that will be described hereinafter in greater detail.For the moment it will suffice to state that the display module 14operates on a direct current low voltage source which is coupled fromthe backside of the billboard 110 to the frontside of the billboard 110.The modular electrical conversion device or display module 14 is furtheradapted to be coupled to a data source via an individual one of theplurality of wire routing paths. Each one of the LED boards, formingpart of the display module or the modular electrical conversion deviceincludes a plurality of electrical elements coupled to the constantpower source and to the data source for converting electrical energyinto visible radiant energy indicative of an electronic message intendedfor pubic viewing.

Finally it should be noted that the structural frame 12 (FIG. 23) has asufficient depth dimension and a sufficient strength construction sothat no unexpected wind loads within normal building code weatherconditions can be expected to overstress a structural frame 12. Tofurther obviate such bending stresses, each structural frame 12 of thebillboard sign 110, has been provided with a sufficiently large numberof restraint/bolt locations, such as a center frame bolt locationfeature 62 and an outside frame edge bolt location 63. These centerrestraint location features 62 are disposed along the center of thestructural frame 12 in a spaced apart manner from the top of thestructural frame 12 to the bottom of the structural frame 12. In asimilar manner the outside frame edge restraint location features 63 aredisposed along the right side edge and the left side edge of thestructural frame 12 from top to bottom of the structural frame 12. Toover restrain the billboard 110 relative to the undersurface posterpanels, if necessary, sash structural frame 12 is further provided withintermediate bolt location features 61 which also extend from the top tothe bottom of the structural frame 12. Such over or excess restraintability built into each structural frame 12 substantially eliminates thedanger of such bending stresses. During installation of the retrofit kit10, a minimum bolt pattern is established based on worst wind loads andthe allowable stress on the frame 12. In short, the new and uniquebillboard 110 is designed to reduce tensile stress and to optimize theload bearing capabilities of the designed billboard structure 110.

The above-mentioned multiple bolt locations 61, 62, 63 also enablesflexibility during the installation of the retrofit kit 10. For example,in order to miss a panel seam in an existing gauge metal structureassociated with a static billboard 8, an installer can easily avoid sucha seam by simply utilizing an adjacent bolting feature. This, in turn,means that during the installation of the retrofit kit 10 less billboardstructural steelwork modifications, if any, are required greatlyreducing installation time. Moreover, it should be further understoodthat because the sealed display modules 14 are removably latched intoplace within respective ones of the bay members 16, such display modules14 can be easily and quickly removed from the frame 12 thereby allowingadditional bolts to be secured to a frame 12 accommodating possiblefuture changes in a building code wind load design should that everoccur. Again this is an important, unique and novel feature of thepresent invention since there is the ability to replace sections of thebillboard 110 without the use of heavy machinery. Moreover, if desiredas earlier-mentioned, the billboard 110 may be easily and quicklydisassembled and transported for installation at another staticbillboard location. For example, first using the dynamic billboard at afootball field and then later using the dynamic billboard at a baseballfield. This is an important and uniquely novel feature of the presentinvention although it is not expected that this feature will be utilizedto any great extent because of the substantially low cost of thebillboard components and labor.

The Poster Panels of an Existing Static Billboard

Since the retrofit kit 10 is mounted to existing poster panels 9 of astatic billboard 8, it should be understood by those skilled in the art,that preparing a site for installation of the retrofit kit 10 is animportant step in the retrofit process. This preparation process will bedescribed hereinafter in greater detail. For the moment; however, itshould be noted that each poster panel 9 that will receive a structuralframe 12 of the retrofit kit 10, must be substantially flat and uniformand cleaned of any residual poster paper. This is necessary since thestructural frames that will be installed, need to be aligned with oneanother, and the structural frames need to lay flat against and inintimate contact with the surface of each poster panel 9. It should alsobe noted that poster panels are an industry standard. They are typicallyconstructed of 20 gauge sheet metal, which is formed into interlockingpanels. The total depth of a poster panel is about 2 inches so the boltsand self-drilling or tek-screws utilized to secure the structural framesto the underlying poster panels 9 can pass through the panels withoutthe use of anything but standard steel drills and the like.

The Compound Structural Frame

Considering now the compound structural frame 12 in greater detail, eachcompound structural frame 12 as earlier-mentioned is composed of astructural foam material, which is a type of cellular plastic with adense outer skin surrounding a foam core. Structural foam was selectedbecause of its light weigh, strength and its ability to be easily moldedto provide the many unique and novel features designed into eachstructural frame 12. In this case, it should be understood thatstructural foam molding is a process for making extremely strong, rigidand light-weight plastic parts and products that have a hard outer “skinor shell” and a hard honeycomb type foamed inner core. The structuralfoam molding process is an extension of a standard injection moldingprocess but is a greatly improved process for the present inventionproviding several unique and important advantages.

For example, using injection molding would be very impractical and costprohibitive for the large 4 foot by 5 foot structural frames of thepresent invention. Moreover, the steel molds required in injectionmolding as opposed to the aluminum molds used in structural foammolding, would present another serious problem relative to costs. Thisdeficiency of injection molding relative to the structural frame 12 ofthe present invention is due to the many built in design features in thestructural frame 12 which help to modularize this component. Forexample, the built in cooling conduits that facilitate a passive coolingstructure without the need for using cooling fans; or the built in nodereceptacles and wire routing paths that facilitate the use of preformedwiring harnesses and the use of jumpers that facilitate redundant datapath resulting in a significant reduction in power and data routingcomplexities but making injection molding quite impractical.

Another unique and important feature of the present invention is thatall power delivered to the structural frame array 30 for use by theinstalled display modules is rectified to less than 30 VDC at thebackside of the billboard 110. This low direct current voltage is thencoupled through a pair of power access holes or opening from thebackside of the billboard 8 to the frontside of the structural framearray 30 where the rectified low voltage power is safely routed within astructural frame array 30 using preformed wire harnesses that will bedescribed hereinafter in greater detail. For now it will suffice tomention that a preformed power/data wiring harness 2400H (FIG. 24C)provides a plurality of preformed nodes or over-mold node features2401-2411, where the preformed nodes are configured to be snapped intoposition in wire harness node receptacle features, such as an upper wireharness node receptacle feature 350 and a lower wire harness nodefeature 351 (FIG. 23), which receptacle features are built into thestructural frame 12. In short, a significant reduction in retrofit timeis achieved by the unique and novel complementary features of structuralframe receptacle coupled with power/data wiring harness over-mold nodefeatures.

Although the time to mount a structural frame 12 of the presentinvention is much greater than the time to mount an LED display module14 of the present invention (due to screw and bolt fastening requirementas opposed to simply positioning and sliding an LED module 14 in placein an associated structural bay member 16 and then latching the moduleinto place), it should be appreciated that the large, hand mountable, 5foot by 4 foot modular structure of each structural frame 12 coupledwith a plurality of row aligned and column aligned structural baymembers 16 configured to receive a universal display module 14, that donot need or require sectional markings or indicia, facilitates quick andeasy installation of the retrofit kit 10 at a low cost. For example, itwould be extremely impractical to need to mount one hundred structuralframes in order to accommodate 100 LED modules where weatherization ofthe frames is in-field labor intensive, whereas weatherization of theLED modules is in-factory labor intensive. From the foregoing, it shouldbe understood that due to yield, weight and manufacturing limitations,the structural frames 12 and the LED display modules 14 of the presentinvention, are each optimized in size and in ease of in-fieldinstallation to be fully protected against building code weatherconditions.

From the foregoing, those skilled in the art should clearly understandthat the structural frame 12 is designed with the following unique andnovel features as part of the retrofit kit 10: (1) each frame 12 iscomposed of light weigh durable structural foam which is sufficientlylight in weight that the frame can be easily lifted and installed by asingle worker without the need of a crane or any other heavy liftingequipment; (2) each frame is modularized with build in design featuresthat not only help substantially minimize retrofit kit installationtime, but which also reduce operating costs; (3) each structural frame12 is identical, and may be easily and simply reduced in size to itlowest modular structure for duplicative installation weatherizingprocesses; (4) each structural frame 12 is identical and easy to installwhich minimizes the skill level required for installing the retrofit kit10; (5) each structural frame 12 has built in cooling vents capabilitiesthus, avoiding complicated cooling schemes with electrical cooling fansand the like for the on-board electronics; and (6) each structural frame12 is protected from insect infestation and is further protected fromunwanted and undesired small animal and bird invasion.

Over-Mold Node Locators and Node Receptacles

Considering now the structural frame 12 in still greater detail, eachstructural frame 12 is provided with the capability of accepting inpredetermined cable routes preformed power and data cable harnesses,such as the power and data harness 2400H as best seen in FIG. 24C. Inthis regard, each column of structural bay members 16 is provided with atotal of 6 over mold node receptacle features which extend from the topof the structural frame 12 to the bottom of the structural frame 12. Inthis regard, each structural bay member 16 is provided with a singleupper over mold node receptacle feature 350 (FIG. 23), but only thebottom row of structural bay members 16 is provided with a pair of overmold node receptacle features, namely the upper wire harness nodereceptacle feature 350 and a lower wire harness node receptacle feature352. This is an important and novel configuration as the extra or lowerwire harness node receptacle 352 will cooperate with a powerintroduction over mold node 2406PS (FIG. 14) forming part of the powerdata harness 2400H to facilitate a 10AWG wire spliced to a 14AWG wiremidway in the associated power data harness 2400H as best seen in FIGS.24C and 28. When two structural frames, such as the structural frame 12,are aligned one on the bottom and one on the top as best seen in FIG.23, the above-mentioned splice takes place between in the bottom row ofthe top frame 12 or between the 5^(th) and 6^(th) over mold nodelocators of the harness 2400H as will be explained hereinafter ingreater detail. For now it will suffice to state that this quick andeasy “snap in place” process, using the over mold nodes of the preformedharness 2400H and the wire harness node receptacles 350 and 352 of thestructural frame 12 facilitates quick and easy of installation of thepower and data wiring harnesses required by the billboard 110. As all ofthe power data harnesses 2400H are identical in structure, an installersimply starts by snapping in respective ones of the over mold nodes intotheir respective ones of over mold node receptacle from top to bottom inthe columns of structural bay members (FIG. 28). This wiringinstallation process therefore is accomplished in a very fast andconvenient manner without the need of using complex and unnecessarynode/receptacle identification indicia markings. In short, thestructural frame 12 and the wire harnesses, such as the preformed wireharness 2400H cooperate with each other to provide a very efficient andnovel data and power routing system because of the build in design ofwire routing features found within each structural frame 12.

As noted-above, the over mold node receptacles 350 and 352 in eachcolumn of structural bay members 16, define a built-in power and datarouting features within each structural frame 12 which coupled with thesimple, easy to snap in place power data harnesses, such as a power/dataharness 2400H, facilitates quick and easy installation of the retrofitkit 10. The over-mold node features 2401-2405, 2406PS and 2406-2410 andthe wiring harness node receptacles 350-351 are an important and uniquefeature of the present invention since these features in combination notonly help expedite locating the routing and installation paths for thedata power wiring, expedite inter-connections within the structuralframes 12, but they also help prevent harness damage during installationby helping to prevent the power and data harnesses from becoming tangledin bundle of wires which could be easily pinched and damaged duringlater installation of the display modules 14. It should also beunderstood by those skilled in the art that by limiting all the HVACwiring to the backside of the poster panels and only passing low voltageDC power through to the frontside of the poster panels and structuralframes 12 an outstanding safety feature is achieved. That is, when aninstaller or maintenance person is working on the billboard 110 from thefrontside of the billboard, that person will never be exposed to HVACpower. In short, the installer or maintenance person is protected fromunwanted and dangerous electrical shocks when removing and replacingdisplay modules from the frontside of the billboard 110 or when makingany repairs on the frontside the billboard 110.

The Display Module

Considering now the sealed display module 14 in greater detail withreference to FIGS. 8-11, each hand mountable display module 14, iscompletely weatherized, self contained and ready for quick and easyinstallation in a bay member 16 forming part of a structural frame 12.The display module 14 generally has a longer horizontal dimension thanvertical dimension and is arranged generally in about a one foot by twofoot rectangular configuration. In this regard each LED display module14 is optimized in size for the structural bays of the presentinvention. As mentioned herein, each structural frame 12 may be reducedin size from it standard height width configuration to a smallerconfiguration if needed. In this smallest configuration, which isachieved by using a skill saw to separate the smallest configurationfrom the balance of the frame, the resulting structural frame 12 stillhas the ability to receive within its associated structural bay member16 a single display module 14. In short then, the display module 14 isoptimized in size and weight thereby substantially reducing the cost ofreplacement should a module 14 fail. That is, if this optimization wasnot achieved, and the display module was substantially larger in size,not only would the increased size, increase weight, but it would furtherincrease the impact of a manufacturing defect failure with a resultingincrease in cost. Yield and weight are therefore important trade offsagainst the need to install a greater number of modules.

As best seen in FIG. 10, which is an exploded view of the display module14, the display module 14 generally includes an LED frame 201 which isconfigured to receive two side-by side LED display panel assemblies,namely a left side display panel or PCA assembly 14L and a right sidedisplay panel or PCA assembly 14R, where each display pane assembly 14L,14R has a vertical dimension, and a horizontal dimension whichdimensions are substantially equal in length. A frontside 201F of eachLED frame 201 is adapted for receiving and supporting therein the leftside printed circuit assembly (PCA) 14L, and a right side printedcircuit assembly (PCA) 14R. The left PCA 14L is received on a front leftside 201FL of the LED frame 201, while the right PCA 14R is received ona front right side 201FR of the LED frame 201. For clarity purposes theprinted circuit assemblies 14L and 14R are illustrated at the backsideof the LED frame 201 although as above-noted, each assembly is installedin the frontside 201F of the LED frame 201.

The display panel assemblies 14L and 14R are each configured in about aone foot by one foot arrangement abutting one another as best seen inFIG. 25. Each display panel assembly 14L and 14R, provides a displayarray of two hundred and fifty six pixels, where each pixel is definedby a set of three different color light emitting diodes, namely a redcolor generating LED 225R, a green color generating LED 225G, and a bluecolor generating LED 225B as best seen in FIG. 16. The individual LEDs225R, 225G, and 225B combine to provide a three color pixel whichconverts electrical energy into visible radiant energy, which visibleradiant energy is cast outwardly from the surface of the display module14 to display information in recognized light patterns of images andtext when viewed as a total assembly of light emitting diodes. In orderto help substantially reduce ambient light effects, each display panelassembly 14L and 14R is provided with a louver in the form of a leftfrontside louver 17L and a right frontside louver 17R respectively. Thefrontside louvers 17L and 17R are adapted to be mounted to the face ofrespective ones of the printed circuit assemblies 14L and 14R on LEDframe standoff features and a set of 13 screws (black paint, M2.6×8 mm)per side. Please note, that for further clarity purposes, with referenceto FIG. 10, each of the PCA assemblies 14L and 14R respectively areshown with only a single light emitting diode 225R.

As already earlier-noted each display module 14 also includes acentrally disposed daughter board 20 which handles the transfer of databetween each of the display panel assemblies 14L and 14R respectivelyand also distributes power for use by the individual light emittingdiodes. The electronic structure of the daughter board 20 will bedescribed hereinafter in greater detail. For the moment, it will sufficeto mention, that the daughter board 20 is adapted to be mounted to thebackside of the LED frame 201 centrally disposed between the two PCAassemblies 14L and 14R. This center mounting arrangement is an importantand unique feature of the present invention. In this regard, thisarrangement, (1) enables a single power and data control board 20 todrive two separate display panel assemblies 14L and 14R respectively;and it also (2) enables the heat generated from driving the large bankof light emitting diodes associated with the display module 14 to bedissipated rearwardly into a large daughter board heat sink 24. Asalready mentioned, and as best seen in FIG. 7, the heat sink 24 isdisposed within a cooling vent 91, when the display module 14 is latchedwithin an associated structural bay member 16. The manner in which thecomponent parts of the display module 14 are factory assembled will bedescribed hereinafter in greater detail.

Detailed Construction of the Structural Frame

Considering now the structural frame 12 in still greater detail withreference to FIGS. 4-7 and 23, the structural frame 12 is configured inabout a 4 foot wide by 5 foot high modular unit composed of structuralfoam. The structural frame 12 is a compound structure since it containsten substantially identical structures in the form of structural baymembers, such as the structural bay member 16. Each bay member 16 asearlier-mentioned is adapted to receive and support therein a displaymodule 14. As the structural bay members are substantially identical instructure, only one of the structural bay members will be described;however, as needed, any structural bay having a unique feature from anyother structural bay members 16 will also be described. For example, asalready discussed, the bottom row of structural bays in a structuralframe 12 includes an extra or lower over mold node receptacle 352 (SeeFIGS. 4 and 23). The bottom row of structural bay members 16 alsoinclude an extra set of wire routing features, such as a left side wirerouting feature 308 and a right side wire routing feature 310 that willbe described hereinafter in greater detail. The wire routing features308 and 310 as well as the lower over mold node receptacle 352 are notfound in the other four rows of structural bay members 16. Thesefeatures are only found in the bottom row of structural frame baymembers 16. This again, is an important and unique feature of thepresent invention, as it as will be described hereinafter in greaterdetail. For the moment, it will suffice to mention that these featuresenable routing of the data connection cables 2400DC (FIG. 24B) alongthis bottom row of the frame array 30 as best seen in FIG. 17. In a likemanner, these features will help facilitate coupling power wiring fromthe frontside of the billboard to the backside of the billboard 110 aswill be explained hereinafter in greater detail. Based on the foregoing,it should be understood, those structural frames with these uniquefeatures will always be installed in the 1^(st) and 6th rows of theframe array 30.

Considering now the structural bay member 16 in greater detail withreference to FIGS. 4-7, the structural bay member 16 generally includesa plurality of irregularly shaped weight reduction cutout areas, such asa top left weight reduction cutout area 312, a bottom left weightreduction cutout area 313, a top right weight reduction cutout area 315,a bottom right weight reduction cutout area 316 and a pair of centerright weight reduction cutout areas 317 and 318 which are adjacent toweight reduction cut out areas 315 and 316 respectively. The pluralityof weight reduction cutout areas 312-318 are strategically positioned soas not to compromise the structural integrity of the structural frame 12and to provide access areas for installer to easily reach power and dataharnesses, wire routing hooks, and over mold node receptacles. In thisregard, harnesses, jumper and connection cables can be easily routed andsecured within the bay members and secured to wiring harness nodereceptacles, such as the upper wire harness node receptacles 350, thelower wire harness node receptacles 351, which receptacles form part ofeach structural bay member 16.

As mentioned earlier, the bottom row of the structural bay members asbest seen in FIGS. 4 and 23, include unique features not found in theother rows of structural bay members. As a result of these extrafeatures, the other rows without these features are provided withdifferent shaped cutout areas indicated generally as an expanded bottomleft side cutout weight reduction area 304 and an expanded bottom rightside cutout weight reduction area 306 as best seen in FIG. 23.

The wire harness node receptacles 350-351, are an important and uniquefeature of the present invention as they allow power and data wiringharnesses, such as the power data wiring harness 2400H, to be quicklyand easily snapped into place within the frame array 30, which in turn,makes assembly of the plurality of harnesses 2400H into the array 30very efficient while at the same time helping the installer to easilyorganize the power and data wiring of each of the structural bay members16.

Each structural bay 16 further includes a plurality of latch receivingboss areas, which are oriented either in a lateral direction relative tothe structural frame 12 or in a vertical direction relative to thestructural frame 16. The latch receiving boss areas are further orientedto receive a frame latch assembly, such as a frame latch assembly 412 asbest seen in FIG. 5 within associated latch latching member 416extending upwardly, downwardly, to the right, or to the left so that theLED tile or display module 14 secured by the respective different onesof the latch assemblies 412 is protected against unwanted and unexpectedwind load forces within the scope of building code requirements. In thisregard, there are two +Y latch receiving boss areas; including an upperleft side +Y latch receiving boss area 322 and an upper center +Y latchreceiving boss area 323; a single left lower side −X latch receivingboss area 324; an upper right side +X latch receiving boss area 327, andtwo −Y latch receiving boss areas, including a lower center −Y latchreceiving boss area 325 and a lower right side −Y latch receiving bossarea 326. Each of the latch receiving boss areas 322-327 have pairs oflatch mounting holes, such as a pair of latch mounting holes 320 and 321respectively, which holes 320-321 are dimensioned for receiving a latchmounting rivet 419 to facilitate mounting the frame latch assembly 412within its corresponding latch receiving boss area.

The orientation of the latch receiving boss areas 322-327 and theirassociated frame latch assemblies 412 is another important and novelfeature of the present invention. In this regard the latching action ofthe individual frame latch assemblies 412 disposed in boss areas 322 and327 are diagonally opposed in the ±Y directions, while the latchingaction of the frame latch assemblies 412 disposed in boss areas 324 and325 are diagonally opposed in the ±X directions, and finally, thelatching action of the frame latch assemblies 412 disposed in boss areas323 and 326 are oriented in opposition to one another along a centralaxis of the structural bay member 16 in the +Y and −Y directionsrespectively. From the foregoing, it should be understood themulti-latching-directions as described herein assures that a LED displaymodule 14 is completely protected from unwanted and unexpected windloads. As will be explained hereinafter in greater detail, each displaymodule 14 includes a corresponding or complementary set of latchreceiving receptacles, such as a display module latch receivingreceptacle 14LM as best seen in FIG. 9. In this regard, the modulereceiving receptacles 14LM are oriented similarly to the frame latchassemblies 412, in order to facilitate latching engagement withrespective ones of the latch assemblies 412 mounted within respectiveones of the structural bay members 16. For now, it will suffice tomention, that because of the unique modular construction of both thestructural frames 12 and the display modules 14, the display modules ofthe present invention may be installed in any structural bay member 16within the frame array 30. In short, there is no need for identifyinginstallation location indicia within the frame array 30 for individualone of the display modules 14, as their placement is universal withinthe frame array 30.

Each structural bay 16 further includes a centrally disposed daughterboard receiving cut out area 330 (FIGS. 4-5) which is disposed betweenthe left side weigh reduction cutout areas 312-313 and the right sideweight reduction cutout areas 317-318. The daughter board cut out area330 is strategically positioned within the center of the structural baymember 16 directly over a structural frame lateral rear inside wall area319 (FIGS. 6-7) that helps to define a vent column or cooling conduit,indicated generally at 91 in the structural frame 12. In this regard, acooling conduit is formed when the structural frame 16 is secured withit rear face against the forward or front face of the poster panel 9disposed directly rearward of the structural frame member 12. Thisdaughter board cut out area 330 is sufficiently large to allow the heatsink fins 24F of the display module 14 mounted within such a cutout areato be disposed directly within the air path of the cooling conduit 91 asbest seen in FIG. 7. In this manner, natural air flow along this coolingconduit 91 is sufficient to substantially cool a plurality of displaymodules which are similarly disposed in the same cooling conduit. Forexample, billboard 110 which is illustrated as being constructed withten (10) structural frames 12 arranged in two rows and five columnswould be provided with ten (10) structural bay members 16 in each row ofthe structural frames 12, and twenty (20) structural bay members 16 ineach of ten column of structural frames 12 as best seen in FIG. 27. Thisarray 30 of structural frames therefore, would include two cooling vents91 in each structural frame 12 column, so a total of twenty coolingvents would be distributed across the entire frame array 30 given byequation 2:Total Number of Cooling Vent=(10 Columns×2 Vents/Column)=20 CoolingVents   [Equation 2]This in turn means that a total of 20 chimney vent locations would bedisposed across the top and bottom of the structural frame array 30.

As already explained, labor costs are greatly reduced relative to usingthe retrofit kit 10 to convert a static billboard 8 into a dynamicbillboard 110 because for a 11 foot by 22 foot billboard sign onlyrequires ten (10) structural frames and one hundred (100) completelyweatherized LED modules 14. To help minimize the time to install astructural frame so that the frame 12 is also completely weatherizedagainst building code weather conditions, each structural frame 14 isprovided with a pilot hole feature, such as a pilot hole feature 64 asbest seen in FIG. 4. The pilot hole feature 64 is disposed in the bottomrow of structural bay members 16 and therefore this feature helps aninstallers immediately identify the top and bottom of each structuralframe 16 for frame array 30 mounting purposes. As will be explainedhereinafter in greater detail the pilot hole feature 64 also helps aninstaller to determine where access holes 114H-116H (FIG. 17) will bedrilled in the frame array 30 for routing power and data wiring withinthe structural frame array and out to the backside of the billboard 110for connection to power junction boxes and a power data controllerenclosure box as will be explained.

Considering now the frame latch assembly 412 in greater detail withreference to FIG. 30, the frame latch assembly 412 generally includes aframe latch housing 414 and a frame latch latching member 416. Thehousing 414 and the frame latch latching member 416 are adapted to besecurely mounted within a latch receiving boss area of the structuralbay member 16 as previously discussed. In this regard, the propermounting orientation of a frame latch assembly 412 relative to anassociated receiving boss area is done quickly and easily by theorientation of the boss receiving areas. In other words, a frame latchassembly 412 can only be received within a boss area in the correctmating orientation. Once the frame latch assembly 412 has been receivedor mounted within a boss area it is secure within the boss area by aframe latch assembly mounting rivet 419 which fastens the assembly 412to the structural bay member 16 of the structural frame 12. It iscontemplated that in order to expedite field installation time of theretrofit kit 10, that frame latch assemblies, such as the frame latchassembly 412 will be secured by a rivet to the structural frame 12 atthe factory during structural frame construction time at the location ofa structural frame vendor, rather than installing the latch assemblies412 in the field.

Detailed Construction of the Display Module

Considering now the display module 14 in still greater detail withreference to FIGS. 10-11, 13 and 32-33, in order to facilitate thedistribution of data and low voltage power, each display module 14 isprovided with an integrated circuit assembly as the heretofore mentioneddaughter board 20. The daughter board 20 is mounted to an LED frame 201.FIG. 32 is a backside view of the LED frame 201, and FIG. 33 is afrontside view of the LED frame 201, without the daughter board 20 beingmounted thereto. Referring again to FIGS. 10-11, the daughter board 20generally includes a printed circuit board 21 having mounted thereon amicro-controller which is disposed in an integrated circuit can 26 and adirect current to direct current converter 25. The micro controller 26functions as an input/output data transferring device which ismechanically and electrically coupled to a twelve-pin power and dataconnector, indicated generally at 27. The connector 27 is mounted to theprinted circuit board 21 and is adapted to be connected to a matingpower and data connector 2400HM forming part of a set of preformed powerdata harnesses, such as the harness 2400H. The power data harnesses2400H distribute power and data throughout the array 30 of structuralframes as best seen in FIG. 17. The direct current to direct currentconverter 25 includes a left side low voltage channel 70 and a rightside low voltage channel 72 for distributing a stepped down low voltagefrom 24-30 VDC to 4 VDC for use by the individual light emitting diodes,for example diodes 225R, 225G and 225B (and their drivers), forming thepixel structures on the display panels 14L and 14R respectively. Thedaughter board 20 also includes a daughter board dam, indicatedgenerally at 22, which is adapted to be secured to the printed circuitboard 21 by screws (not shown) through the plastic frame. The daughterboard dam 22 overlays a thermal pad forming part of the DC-to-DCconverter 25. The dam 22 allows for an isolated increased potting depthat the connector, which is aligned to the board before the dam 22 isplaced in position. The dam 22 also facilitates the mounting of thedaughter board heat sink 24 in proper orientation to the othercomponents of the daughter board 20.

To facilitate distribution of data and power to respective ones of thedisplay panels 14L and 14R, the daughter board 20 is further providedwith a pair of spaced apart pin headers, including a left side pinheader 28LSPH and a right side pin header 28RSPH which in combinationwith the power data connector 27 enables the display module 14 to beelectrically and mechanically coupled to the power data distributionsystem 120 as will be explained hereinafter in greater detail.

As already mentioned, the display module 14 generally includes a leftside PCA display panel assembly 14L and a right side PCA display panelassembly 14R. As will be described shortly, and as best seen in FIG. 10,the left side PCA assembly 14L includes a printed circuit board 610,while the right side PCA assembly 14R includes a printed circuit board612. Sometimes during the following detailed description of the assemblyof the display module, the term PCA assembly 14L may simply mean theprinted circuit board 610 with loaded light emitting diodes. In asimilar manner the term PCA assembly 14R may simply mean the printedcircuit board 612 with loaded light emitting diodes. This occurs becauseonce the assembly of the display module 14 has been completed the leftside PCA assembly 14L and the right side PCA assembly 14R are adhesivesecured to the LED frame on their respective front left side 201FL andfront right side 201FR and can not be removed individually from the LEDframe 201. The above described terminology therefor occurs during thoseinstances where the PCA assemblies 14L and 14R have not been adhesivesecured to the LED frame 201 and it is utilized simply for that purpose.

Considering now the PCA assembly 14L in greater detail, the PCA assembly14L generally comprises a printed circuit board 610 which is providedwith a plurality of pairs of LED mounting holes, such as LED mountingholes 620-621 as best seen in FIG. 31. The LED mounting holes 620-621are dimensioned for receiving and surface mounting individual ones ofthe LEDs 225R, 225G and 225B. In this regard, the positive and negativeleads of the LEDs are received in their respective mounting holes,trimmed and soldered to the printed circuit board 610, until all the LEDmounting holes disposed on the printed circuit board 610 have beenloaded. The printed circuit board 610 is also provided with a set oflatch access holes, such as a latch access hole 634 that enablesfrontside access to the structural frame latch assemblies and theiractuators, such as an actuator 418 as best seen in FIG. 30. The printedcircuit board 610 also includes a set of header pin mounting holes,indicated generally at 635. These header pin holes indicated at 635 aredimensioned for receiving a set of header pins, which extend outwardlyfrom the connector 28LSPH mounted to the daughter board printed circuitboard 21. The PCB assembly 14R, since it is mounted to the right side ofthe LED frame 201, has its header pin mounting holes 635 disposed on thecenter left side of its associate printed circuit board 612. Indiciamarkings, such as the indicia marking indicated generally at 637 providean assembler a visual indication of whether a given board is to bemounted on the top left side of the LED frame 201 or on the top rightside of the LED frame 201. This orientation is important as it providesan indication of a further position reference so the latch access holes634 in the printed circuit board 610 are placed in their properorientation to the other component parts of the display module 14.

As best seen in FIGS. 10 and 32-33, the left side PCA 14L is adapted tobe securely mounted to a front left side 202FL of the LED frame 201. Ina similar manner, the right side PCA 14R is adapted to be securelymounted to a front right side 201FR of the LED frame 201. For themoment, it will suffice to mention that the left side PCA 14L isprovided with a left side pin header slot or opening, indicatedgenerally at 211, while the right side PCA 14R is provided with a rightside pin header slot 212 which is larger than slot 211 as it furtheraccommodates the power data connector 27 as best seen in FIG. 33. Theseslots 211 and 212 are utilized for aligning and helping to mount thepower data connector 27 and the left side pin header 28LSPH and theright side pin header 28RSPH of daughter board 20 to the LED frame 201.In this regard, the daughter board 20 is mounted by a pair of screws(not shown) to a centrally disposed dam receiving space or areaindicated generally at 214 on backside 201B of the LED frame 201.

To facilitate these various mounting tasks, the frontside 201F of theLED frame 201 is provided with a set of alignment mounting features,such as an alignment mounting 204 (FIG. 33), while the individual onesof the printed circuit board assemblies 14L and 14R are each providedwith a plurality of alignment holes, such as a left side alignment hole630 as best seen in FIG. 31. In this regard, during assembly of anindividual one of the display modules 14, which assembly occurs in afactory setting and not on-site or in-the-field, an assembler will lineup the plastic stand-off features 204 disposed on the front left side201FL of the LED frame 201 with the left side alignment holes 630disposed in the left side PCB 610. Each individual one of the printedcircuit board assemblies 14L, 14R is marked with orientation indicia inthe form of a left or right arrow indicating which side of the PCA isup. Assembly continues by the assembler making certain that the PCB 610is push down flush within the front left side 201FL the LED frame 201.This alignment and mounting procedure is repeated for the front rightside 201FR of LED frame 201 and the right side PCB 612. Once the printedcircuit board assemblies 610 and 612 are mounted flush to the LED frame201, they are then secured to their respective frame sections utilizinga set of seventeen (17) Zinc plated, M2.6×8 mm screws with a torquedriver set to 5 inch pounds.

Considering now the weather sealed display module 14 in still greaterdetail with reference to FIGS. 10-11 and 32-33, the LED frame 201, isprovided with a set of daughter board alignment features, such as analignment feature 206 as best seen in FIG. 33. The daughter boardalignment features 206 facilitate assembly of the daughter board 20 to abackside of the LED frame 201. In this regard, with the LED frame 201flipped over onto a soft ESD sage surface, the daughter board alignmentfeatures 206 are clearly seen and are utilized to mount the daughterboard 20 to the LED frame 201. As best seen in FIG. 11, the circuitboard 21 forming part of the daughter board 20, has a corresponding setof alignment features in the form of a set of alignment holes 207 and208 respectively. The alignment holes 207 and 208 are dimensioned toreceive therein the alignment posts 206 of the LED frame 201.

During assembly, after the board 21 has been mounted to the LED frame201, the alignment holes 207, 208 are sealed with a standard industrialsilicone sealing agent. Once the alignment holes 207 and 208 are sealed,the power data connector 27, which is a standard Molex connector, andthe left side pin header 28LSPH and the right side pin header 28RSPH arealigned with their respective header openings 211 and 212 in the leftside PCA 14L and the right side PCA 14R, while the pins of the datapower connector 27 are aligned within the alignment opening 212. Theconnector body of the power connector 27 is further aligned with aplastic dam alignment feature 230 which is disposed on the backside theLED frame 201. When so aligned, the daughter board 20 is then pusheddownward into place until it is flush with the LED frame 201.

To facilitate correctly mounting the brick 25, the brick 25 is providedwith a set of off set holes (not shown) which should be aligned towardthe center of the daughter board 20 over the large integrated circuitsdisposed on the daughter board 20. Once the brick 25 is mounted, then athermal gap pad 25A is mounted to brick 25.

Next in the assembly process of the display module 14, a bead ofindustrial silicon is deposited around the edges 22E of the daughterboard dam 22. This bead of silicon material forms a dam around theconnector pins of the power data connector 27. The daughter board dam 22is then installed over the daughter board 20 with the silicone side ofthe dam 22 and against a corresponding centrally disposed dam featureindicated generally at 233 (FIG. 32) forming part of the LED frame 201.The daughter board dam 22 is then secured in place over the daughterboard 20 with a single screw (Zinc plated, M3×15) with a torque driverset to 5 inch pounds. This structure forms a seal preventing pottingmaterial that will be introduced from leaking away from the daughterboard 20.

With the daughter board dam 22 and thermal gap pad 25A installed, thedaughter board heat sink 24 is then mounted to the dam 22 with a set ofsix (6) Zinc plated screws (M3×15). The heat sink screws further securethe dam 22 to the LED frame 201. It is important to note that the screwsfor securing the heat sink 24 to the dam 22 must be followed in a directsequence as follows: first in the middle left, second in a top right,third in a top left, fourth in a middle right, fifth in a bottom left,and sixth in a bottom right. This order reflects that the headerconnector on the right hand side of the assembly.

Next, the left side pin header 28LSPH is soldered to the face of theleft side printed circuit board 610 or PCA 14L, while the right side pinheader 28RSPH is soldered to the right side printed circuit board 612 orPCA 14R. The frontside of the display module 14 is then potted using astandard potting compound, such as a potting compound manufactured andsold by Shin-Etsu Chemical Co. Ltd. of Tokyo, Japan, identified as their3 component mat surface potting material KE-1283. In this regard, thepotting is poured to substantially a 3 millimeter depth and then curedin an oven at ninety (90) degrees Centigrade for about 30 minutes. Thepotting in this case must cover every exposed surface area of theprinted circuit boards 610 and 612 but without allowing any of thepotting material to touch the tips of the light emitting diodes mountedin their respective printed circuit board assemblies 14L and 14R.

After the display module 14 has been removed from the oven and allowedto cool, the left side louver 17L is install to the face of the leftside printed circuit board assembly 14L using a set of thirteen screws(black paint, M2.6×8 mm) per side. A louver visor 17V (FIG. 10) isdisposed at an edge portion on one side of the frame 201 but not on theother side. That side with the visor 17V is a top side and is installedaccordingly so that when the display module 14 is in the uprightposition, the top row of light emitting diodes mounted therein will allbe red light emitting diodes.

Next, the daughter board dam 22 is potted with a standard pottingcompound, such as a potting compound manufactured and sold by Shin-EtsuChemical Company, Ltd as identified earlier. In this regard, the pottingof the daughter board dam 22 must be followed in a direct sequence asfollows: first that side opposite the power data connector 27 startingwith the dc-dc brick side first. This area is filled with a sufficientamount of potting material until the potting material is level with thebottom of the aluminum extrusion of daughter board heat sink 24. Next,the power data pins are encapsulated with the potting compound, which isa sufficient amount of potting material, is poured over the pins untilthey are completely covered. Finally, the balance or rest of thedaughter board dam 22 is filled ensuring that all areas and allcomponents of the daughter board 20 are completely covered.

As a final step, a set of perforated potting troughs, such as anelongate perforated potting channel 232 having a plurality ofperforations, such as a perforation 234 disposed along it bottom trougharea are disposed on the rear or backside of each of the printed circuitboard assemblies 14L and 14R respectively are filled to a depth of about2 millimeters with a standard potting compound, such as a pottingcompound manufactured and sold by Shin-Etsu Chemical Company, Ltd.identified earlier. Once all the troughs are filled, the display module14 is placed in an oven at ninety (90) degrees Centigrade for a periodof about 30 minutes to allow the poured potting compound to sufficientlycure. The display module is then removed from the oven and allowed tocool.

As noted earlier, the assembly process followed for assembling eachdisplay module 14 is done at a factory and not on-site or in-the-fieldwhere the conversion process is being performed. In this regard, theretrofit kit 10 is provided with a set of completely assembled displaymodules, such as the sealed display module 14. Each sealed displaymodule 14 then is completely weatherized and made immune to invasion byinsects and other small animals. This is an important feature of thepresent invention. FIG. 18 provides a flowchart depiction of the displaymodule board 14 assembly processes.

Considering now the display modules in still greater detail, eachdisplay module 14 is provided as a completely sealed printed circuitboard assembly which is substantially rectangular in shape with a long Xaxis, an intermediate Y axis, and a short Z axis. Each module 14 iscompletely sealed from the outside and each display module 14 as bestseen in FIGS. 8-9 has a frontside 215 and a backside indicated generallyat 216. The backside 216 has a plurality of module alignment features,such as a module alignment feature 14AR and 14CAR. The individualalignment features 14AR and 14CAR extend along the short Z axis of themodule 14. The backside 216 also has a plurality of latch receivers,such as a latch receiver 14LM. The individual ones of the latchreceivers 14LM each have a latch access opening or cutaway areaindicated generally at 220 which openings 220 are dimensioned to receivetherein a module latch 416 forming part of latch assembly 412 mounted onthe frontside of the structural frame array 30. In operation, when alatch 416 is received within an individual one of the latch receivers14LM, the latch 416 and latch receiver 14LM cooperate to pull thedisplay module 14 into its associated structural bay member 16 whilesimultaneously applying a retaining tension so the display module 14 isheld in a tight fit within its associated structural bay member 16 ofthe structural frame array 30.

A total of six (6) module latches receivers 14LM are provided on eachdisplay module 14 and these receivers 14LM are aligned to receive thestructural frame latches, such as a latch 416. In this regard, thereceiver latch openings 220 are configured to receive an associatedmodule latch 416 in generally a lateral direction which is parallel tothe XY plane of the display module 14. In this regard, two of the latchopenings 220 receive a module latch 416 in the +Y direction, two of thelatch openings 220 receive a module latch 416 in the −Y direction, oneof the latch openings 220 receive a module latch 416 in the +Xdirection, and one of the latch openings 220 receive a module latch 416in the −X direction. Stated otherwise, the module latches receivers 14LMand the structural frame latch assemblies, such as the latch assembly412 are arranged in a generally zigzag layout pattern which allows forflexibility during installation but more importantly and which isconsidered a unique and novel feature of the present invention. In thisregard, the zigzag layout optimizes and protects each module display 14from being dislodged from its structural bay member 16 due to unexpectedhigh force gusts of wind. It is in this manner, each individual displaymodule 14 is firmly and securely latched within an associated structuralbay member 16. Each individual latch receiver 218 further has disposedadjacent to it a tool access opening indicated generally at 224, whichis best seen in FIG. 32 which is a back plane view of the LED frame 201.Each tool access opening 224 is dimensioned and configured to receivetherein an actuation tool 912 for engaging and actuating the modulelatch actuator 418 associated with its latch 416 (FIG. 30).

In summary then, as best seen in FIG. 18, a display module manufacturingprocess 6010 begins with a start step 6012, and immediately advances toa fabricate a printed circuit board assembly step 6021. At thefabrication step 6021, a printed circuit board assembly, such as the PCA14L is assembled as described earlier herein. The manufacturing processcontinues to an assembly step 6032, where the individual PCA units 14Land 14R are attached to the frontside 201F of the LED frame 201 by a setof fasteners (not shown).

Next, at an assembly step 6036, an assembled daughter board 20, issecured to the backside 201B of the LED frame 201. During this assemblyprocess, the header pins extending from the daughter board 20, from itsleft side and from its right side are received within the header pinmounting holes 635 of respective ones of the printed circuit boards 610and 612 forming part of PCA assemblies 14L and 14R respectively. Next,the daughter board heat sink 24 is attached to the backside of thedaughter board 20 at a form thermal interface step 6040 and itsassociated attach heat sink step 6048.

Next, the now partially assembled display module is tested at a testingstep 6050 to verify that the daughter board 20 and the associated PCAunits 14L and 14R are fully operational. If not operational, the unit isdiagnosed to determine what repairs are necessary to place the assemblyinto an operational condition and repair is made. If the partiallyassembled display module is fully operational, the header pins of thedaughter board are soldered at a solder step 6060 to their respectiveprinted circuit boards.

Once the display module is so assembled, a weather sealing step 6070 isperformed where the perforated adhesive channels 232 of the frame 201are filled with a potting compound adhesive 236 (FIG. 9). This adhesiveflows through the perforations 234 and forms a sealing layer of compoundacross the entire rear surface of the printed circuit board assemblies14L and 14R respectively. The potting compound is allowed to cure in anoven at about 80 degrees Centigrade for about 30 minutes. Once cured,the display module 14 is removed from the oven and turned over to itsfrontside where the assembly process is completed at an attach louversstep 6080. At the attach louver step 6080, the right side louver 17R isattached to the right side display panel assembly 14R and the left sidelouver 17L is secured to the frontside 201F of the left side displaypanel assembly 14L. The manufacturing process then ends at an end orstop manufacturing display module step 6082. An important feature andnovel feature of the present invention is that display modules or tile14 may be installed within any structural bay member 16 forming part ofthe frame array 30. No special marking or indicia is need on any displaymodule 14 to indicate where it should be installed within the framearray 30 and thus, significantly and substantially reducing installationand retrofit time.

The above-mentioned electrical structure of the display module 14 isbest seen in FIG. 13, which is a block diagram illustrating part of thepower data routing system 120 (FIGS. 17 and 26). That is, the power datarouting system 120 is routed and installed both on the frontside ofbillboard 110 via the structural frame array 30 and on the backside ofthe billboard 110 via the various components of the power modificationkit 10C. Each individual display module 14 mechanically and electricallycouples into this power data routing system 110 to provide radiant lightenergy. FIG. 13 therefor is a very simplified electrical block diagramof the display module 14 illustrating its interconnecting electricalcomponent and interconnections that will be described hereinafter ingreater detail. For the moment, it will suffice to mention that thepower requirements for the billboard 110 are determined by the voltagedrop constraints and that routing paths for power data wiring harnessesare fixed by various structural frame features that have been describedherein with greater detail.

Referring now to FIG. 13, the electrical structure of the display module14 is illustrated in very simplified block diagram form, showing thatthe display module 14 generally includes the daughter board 20 and itsassociated LED display panel boards 14L and 14R respectively. Thedaughter board 20 includes an integrated circuit board 21 having mountedthereon a DC-to-DC converter 25 and a micro controller 26. Both theDC-to-DC converter 25 and the micro controller 26 are electricallycoupled between a power data interface indicated generally at 28 andrespective ones of the LED display panel boards 14L and 14R. In thisregard, the DC-to-DC converter 25 is electrically coupled to displaypanel 14L by a left board DC power path 70 and to display panel 14R by aright board DC power path 72. The micro controller 26 is coupled todisplay panel 14L by a left board data path 80 and to display panel 14Rby a right board data path 82.

The power data interface 28 includes direct electrical connections fromthe twelve-pin data/power connector 27 via a power port pin 27P andpower conductor 73 that provides 24 VDC power to the DC-to-DC converter25. The power data interface 28 also includes a direct electricalconnection from the connector 27 via a pair of data port pins 27D1 and27D2 and a pair of data connectors 81 and 83 respectively that provideinput and output data paths to the micro controller 26 and its inputport 261 and its output port 260. In this arrangement, a closed loopdata path is formed between the display panels 14L and 14R respectively.

FIG. 13 also provides a greatly simplified block diagram of theelectronics 29E for each display panel, such as the display panel 14L.In this regard, it can be seen that power conductor 70 supplied thepanel 14L with a rectified direct current low voltage of about 4 VDCstepped down from about 24-30 VDC, which 4 VDC is coupled to each of thelight emitting diodes or modular electrical conversion devices disposedon panel 14L. The data conductor 80 is coupled to 16 channels of lightemitting diode drivers indicated generally at 29L for driving individualones of the red, green, and blue light emitting diodes forming part ofthe electronics 29E. As this same arrangement is implemented for thedisplay panel 14R, it will not be described in further detail for thedisplay panel 14R.

The Retrofit Kit Installation Procedure

Considering now with reference to FIG. 19, a retrofit procedure 1010 isillustrated, which procedure 1010 is followed in accordance with theretrofit steps of the present invention. The retrofit procedure 1010 iscarried out on-site for an existing non-electronic billboard 8, in orderto retrofit or convert the billboard 8 into a dynamic electronicbillboard 110. The retrofit procedure 1010 involves the following majorsteps:

1. Site preparation to verify that an existing poster board isacceptable to overlay with a digital light emitting diode billboard;

2. Structural frame installation to prepare the existing poster panelsof the billboard 8 for the mounting of a plurality of display or lightemitting diode modules, such the fully weatherized LED display module 14as best seen in FIGS. 8-9;

3. Wire harness and backside power installation for providing the bayarray embodied within each structural frame with a source of data anddirect current electrical power;

4. LED display module installation by providing each individual baywithin the bay array with a display module 14 having dual LED displaypanels, such as LED display panels 14L and 14R respectively as best seenin FIG. 25; and

5. A start up and verify operation for signage content and updating.

Each of these major steps will be described hereinafter in greaterdetail, but for now it will suffice to mention, that after verificationof operation, two important follow on steps are considered part of theretrofit procedure 1010; namely:

6. A preventive maintenance and cleaning process; and

7. An actual maintenance and repair process should repair be required.

These last two steps will be briefly described at the conclusion of thedetailed description of the retrofit process 1010.

The Preparation of the Site for Kit Installation

Referring now to FIG. 19, the retrofit procedure 1010 begins with astart step 1012 and commences to a call site preparation step 1014. Atthe site preparation step 1014, the installation team seeks to verifythat the existing poster panels of the static billboard 8 are acceptableto be overlaid with an array of LED display modules, such as the LEDdisplay module 14. In this regard, the team proceeds from step 1014(FIG. 19) to a site preparation process 2010, as best seen in FIG. 20.

Considering the site preparation process 2010 in greater detail withreference to FIG. 20, the process begins at a start step 2014, andproceeds to an inspection step 2026. At the inspection step 2026, theinstallation team conducts a visual inspection of the existing posterpanels, such as a poster panel 9. A poster panel 9 may from time to timehereinafter be referred to as poster board(s), which phrase sterns backto the time when static billboards were constructed of wood instead ofsheets of metal as used in construction today.

During the inspection step 2026 the installation team addresses areas ofthe sheet metal poster panels which may be broken, bent or damaged inany way. The surface of each poster panel 9 is also inspected to makecertain the surface is substantially flat and uniform as possible tofacilitate the proper mounting and installation of each hand mountablestructural frame 12 forming part of the retrofit kit 10. In addressingthese areas the installation team will remove any vinyl or paper leftover from old static paper panel images. The team will further clean thesurface of the billboard panels of any unwanted materials.

Once, the visual inspection step 2026 has been completed at adetermination step 2038, the installation team proceeds to a powerinspect and verification step 2040. If it is determined, that inspectionis not completed at step 2038, the team returns to step 2026 andcontinues as described earlier. Continuing then, at verification step2040, the team begins by simply determining that the billboard site isprovided with acceptable 2-phase, 240 VAC 40 amp power or 2-phase, 120VAC, 80 amp power. It should be understood that when other input poweris provided, for example, when the billboard 110 is being installedoutside of the United States where the countries power is somethingdifferent from the standard U.S. power sources, a power converter 49(FIG. 26) may be installed at an install power converter step 2044 toprovide a rectified power source for the billboard 110. In this regard,the billboard system of the present invention is a universal powersystem fully capable of using any available power source in the world.

After inspection of available power, the team proceeds to a verificationstep 2042 so the team can mark on its installation checkout list (notshown) that proper power has been verified. If proper power has not beenverified the team will either install a power converter 49 at theinstall step 2044 or take whatever other corrective action is necessaryto assure that proper power is available. Once there is a determinationof the availability of acceptable power at a determination step 2042,the installation team follows a safety procedure while working withelectrically components by turning the power off at a main circuitbreaker and then provides the circuit breaker with a lock out tag out inaccordance with local safety regulations. Next the team disconnects anylights remaining from the static display site and the associate wiringthat provided power for illuminating the static display billboard withlight. As a final action, a confirmation step 2050 the team takes aphysical inventory to verify that all parts needed as best seen in FIG.2 are available by cross referencing parts to a provided parts list forthe site billboard 8 which is being retrofit or converted.

After the confirmation step 2050 has been completed, the installationteam proceeds by going to a go to step 2084 and follows a checklist at adetermination step 1016 (FIG. 19). At step 1016, the team verifies thatthe site preparation process performed at step 1014 has been completed.If anything has been overlooked, the team returns to the sitepreparation process 1014 and proceeds as described before until the siteis properly prepared. If the site is properly prepared, the installationteam then advances to a call install step 1018 which causes the team toinitiate a structural frame installation process 3010 as best seen inFIG. 21.

The Structural Frame Installation

The structural frame installation process 3010 (FIG. 21) begins at astart step 3014 which prompts the team to begin preparing the posterpanels of the existing billboard 8. This preparation process is bestunderstood with reference to FIG. 3. At the start step 3014, the teamgathers the necessary tools and chalk to do the preparation task. Aftergathering their materials the team advances to a layout step 3018. Atlayout step 3018, the installation team prepares the poster panels 9 ofthe existing static billboard 8 for installation of the structuralframes, such as a structural frame 12. This preparation begins by theinstallation team using a ladder, a plum line, measuring tape and chalk,to lay out a grid pattern 508 (FIG. 3) on the frontside or face of theposter panel billboard 8. This grid pattern 508 will be a visualindication of the size and pattern of the structural frames that will beinstalled on the billboard 8 for its conversion. This begins with theinstallation team finding a horizontal center point of the staticbillboard 8 and then measuring 10 feet to the left of a horizontalcenter point line 514 at the top and bottom of the billboard 8 and thenrunning chalk lines 512T and 512B respectively. The installation teamthen runs a chalk line 513 from the distal ends of lines 512T and 512Bto mark a left lower corner starting point 520 for the installation of astarting structural frame 12. FIG. 3 provides a visual indication of howthe billboard would appear after the first or initial structural frame12 is installed, while FIG. 27 provides a visual indication of how thebillboard would appear after all of the structural frames in the kit 10,have been installed.

Next, during the layout step 3018, the installation team measures thebillboard 8 to find the vertical center point fine 516 and thenmeasuring one frame height down on the left and right side of thebillboard 8, they run a chalk line 514 between these two points.

Next, at the layout step 3018, using the above-mentioned referencelines, the installation team lays out the grid pattern 508 using a chalkline to represent the size and pattern of the structural frame. The teamthen verifies the grid measurement by measuring the layout diagonally ata verification step 3024 via a pair of corner to corner diagonal chalklines 522 and 524 respectively. It should be understood that theabove-mentioned measurements are not absolute. They can be shiftedhorizontally and or vertically to avoid issues with the billboardstructure when needed. Should this occur at verification step 3024, theteam returns to step 3018 and proceeds as described earlier; otherwise,the team is ready to advance to the next task.

Once the billboard 8 poster panels have been prepared with the gridlayout 508, the team proceeds to an orientation step 3034 thatfacilitates the unpacking and orienting of the structural frames 12 fromtheir packing pallet for installation on the poster panels of billboard8. In this regard, each structural frame 12 is thin and ultra light sothe frame 12 can be easily handled and oriented for installation. Tofacilitate proper orientation, it should be noted that the pilot holefeature 64 which is located in the first or bottom row of the structuralbay member array. In this regard, the pilot hole feature 64 furtherfunction as a visual indicator for where the bottom of each structuralframe 12 is disposed. As will be explained hereinafter in greaterdetail, when the frames are laid out on the panels 9, the pilot holefeature 64 will also be disposed in either a bottom row of thestructural bay members indicated generally at 16B (FIG. 27) or in amiddle row of structural bay members indicated generally at 16M whenconsidered as part of the total frame array 30.

The pilot feature 64 also then provides an indication to theinstallation team of which side of a frame 12 goes up and which side ofthe frame is facing the frontside, since the pilot feature 64 will alsobe disposed on the left side of the structural frame when it is disposedfacing toward the frontside of the billboard 8. During this unpack andorient step 3034, the installation team also designates ahead of timewhich structural frames will be on a lower row of the grid layout andwhich structural frames will be on an upper row of the grid layout. Thisadvance determination is made because it will determine where the uniquechimney vent structures, such as a chimney vent cover 90, as best seenin FIG. 29, will be installed within a structural frame 12 prior to theindividual structural frames 12 being mounted to the poster panels 9 ofthe billboard 8. When the installation team has completed the unpackingstep a determination is made at a verification step 3040 that all thenecessary parts are available to complete installation. The process thenproceeds to a chimney vent installation step 3054.

At the chimney vent installation step 3054, the installation teaminstalls each individual chimney vent cover 90 either in a topstructural frame area or in a bottom structural frame area of the so theinstalled vent cover 90 functions to cap each chimney vent ingress oregress channels 91 relative to all lower frame horizontal surfaces andall upper frame surfaces as best seen in FIGS. 6-7 for example. Eachchimney vent cover 90 is provided with a plurality of perforations, suchas a perforation 90P as best seen in FIG. 29, which is sufficientlysmall to prevent environmental debris such as leaves from clogging thefree air venting system created between the existing billboard 8 posterpanels and the structural frames 12 mounted thereon. The chimney ventcovers 90 also prevent birds and other small animals as well as insectpests from entering and nesting in the cooling channels of the ventingsystem, such as the cooling channel 91 (FIG. 7).

Once the chimney vent covers 90 have been inserted into respective onesof the structural frames 12 at step 3054, the installation team beginsthe actual installation of the structural frames relative to the posterpanels 9 at a align first frame step 3066. During this step 3066, theinstallation team takes the first frame 12 and starting on the bottomleft hand corner of the grid layout 508, the bottom left corner of theframe 12 is positioned at the bottom left corner 520 of the grid chalklines so the bottom of the frame 12 and the left side of the frame fallsin alignment with the left side grid chalk line 513 and the bottom gridchalk line 512B. When the frame 12 is aligned, a member of theinstallation team screws a self-drilling screw, such as Tek screw 92 asbest seen in FIG. 23 into a top mounting hole, a middle mounting holeand a bottom mounting hole on the frame 12, each hole being identifiedin general as a mounting hole 93 for a self drill screw 92. Ifnecessary, these top, middle and bottom mounting screws 92 can berepositioned to other mounting holes 93 on the frame 12 in order toavoid seams in the billboard 8 structure. Four Tek of self drillingscrews 92 are utilized to secure the first frame 12 to the poster board8. For clarity purpose, not all of the mounting holes 93 have beenidentified with reference characters, but their locations within theframe 12 can be clearly seen in FIG. 23. Similarly only two of theself-drilling screws 92 are shown in FIG. 23 for clarity purposes.

After the first frame 12 is secured to the poster panel 9, theinstallation team will install the next structural frame 12 to theimmediate right of the first frame 12. In this regard, a set of dovetailjoints (FIG. 27), such as a set of side frame dovetail joints 84 and aset of bottom frame dovetail joints 86, facilitate a quick and easy,frame 12 to frame 12 alignment processes. Each individual one of thedovetail joints includes a dovetail alignment tab 94 (FIGS. 4-5) and adovetail alignment tab slot 96 (FIGS. 6-7) which is adapted to receivethe tab 94 extending from an adjacent frame or in this case, the secondframe 12. This dovetail arrangement of tab to tab slot alignment assuresthat the second frame is properly aligned with the first frame and isready to be secured in place. It should be noted that the two framesmust be flush to one another for proper installation. The second frame12 is then secured to the poster board 9 using the Tek screws 92provided in the retrofit kit 10. In short then, the second frame 12 isdovetailed in perfect alignment with the first frame 12. This dovetailprocess is then repeated until all of the structural frames as outlinedin the grid have been installed in the bottom row. It should be notedthat when the individual frames 12 are secured to the poster panels 9 ofthe billboard 8, a substantially airtight fit is created between theircontacting surfaces, which in turn creates a pair of self cooling airchannel columns or conduits, such as the air channel column indicatedgenerally at 91 as best seen in FIG. 23. As already noted, and as bestseen in FIG. 7. Prior to installing a frame 12 against the billboard 8poster panels, each of the air channel columns 91 are capped withchimney vent covers 90 as hereinbefore described. In this manner, thecovers 90 can not be removed, once the structural frame 12 is secured tothe billboard 8 poster panels.

When the bottom row of structural frame members 12 has been installed,the installation team verifies that all the frames are in alignment andlined up with the chalk lines and are substantially level. Once thealignment of the bottom row of frames has been determined, theinstallation team installs the top row of frames using a substantiallysimilar procedure starting at the top left and proceeding to the topright. After the top row of frames has been installed the installationteam verifies that the bottoms of the top row of frames 12 is flush withthe tops of the bottom row of frames 12 and that the top of the top rowof frames is in alignment with the top chalk line of the laid out grid.If any adjustments are needed, the installation team makes the necessaryadjustments to achieve an array of structural frames which are inperfect alignment with one another.

Next to make certain the frames are securely fastened to the billboard 8so that they may not be dislodged or come loose during windy conditions,the installation team using a standard drill drills secondary holesthrough the billboard steel frame poster panels for each of thestructural frames 12. Nine holes are drilled for each frame 12 and ninebolts, with associated washers and nuts, are utilized to further secureeach frame to the poster panels 9 of billboard 8. The individual bolts112B are torque to 8-inch pounds and are installed at the bottom leftframe corner, the middle left of the frame, the top left corner, the topright corner, the middle right of the frame, and the bottom right cornerof the frame. To facilitate the installation of the mounting bolts eachstructural frame 12 is provided with a set of mounting bolt holes, suchas a mounting bolt hole 112H as best seen in FIG. 4. In order to avoidissues with poster panel 9 structure flaws or conflicts with structuralseams, the structural frame 12 is provided with an excess number of boltmounting holes 112H along its peripheral boundaries. In this regard, theplacement of the bolts can be distributed to other mounting bolt holes112H if needed.

After all the frames have been secured with mounting bolts 112B, andverified that they are properly secured at a determination step 3068. Ifnot properly installed the team returns to step 3066 and continues asdescribed earlier. Otherwise, the installation team proceeds to aninstall bee stops or plug step at 3069, where a set of bee stops, suchas a bee stop plug 98, are installed into each perimeter opening in thestructural frame array 30. The bee stop plugs 98 are an important andunique feature associated with the structural frames 12. In this regard,the slot 97 disposed in the top, bottom, right side and left side of thestructural frame function as wire routing access hole to enable powerand data wires mounted on the various ones of the structural frames 12to pass from one frame to another frame and ultimately to the poweraccess holes 114H and 115H and the data access hole 116H to traverse tothe backside of the billboard 110 for connection to the power and datacontrol system. The hole or slots 97 on the outside walls of thosestructural frames not butted up against the walls of an adjacent frame12 would otherwise be open allow access to bug, insect, wasps, and bees.By closing these access holes with the plugs 98, bees, wasps, hornetsand the like are stopped from entering the frame array 30 and creatingnesting hives behind the display modules mounted to the frontside of thebillboard. This would otherwise create a safety hazard, as a repair ormaintenance team would never know when a display module 14 was unlatchedand removed, whether a hive of bees or hornets would be disposed behindthe module 14. The installation of the bee stops or plugs 98 completelyeliminates this unwanted safety hazard.

With the bee plugs 98 in place, the installation team is now ready tomechanically and electrically couple the frame 12 to a source ofelectrical power. In this regard, the installation process returns todetermination step 1020 via a go to step 3070 (FIG. 21), where the teamverifies that all the structural frames 12, all the chimney vent covers90 and all the required bee stops or plugs 98 have been properlyinstalled and that wiring of the structural frames is now ready to becommenced. If verification is not made at determination step 1020, theprocess returns to the install step 1018 (FIG. 19) and proceeds asdescribed before.

The Wire Harness Installation

From the determination step 1020, the team advances to a call installwire harnesses step 1022 which initiates an install wire harness process4010, as best seen in FIG. 22. The process 4010 begins at a start step4014 which directs the team to a drill access hole step 4018. At step4018, the installation team drills a pair of power access holes 114H and115H in the frame array 30 as indicated in FIG. 17. These access holes114H and 115H are drilled at the pilot features 64 disposed in the6^(th) row of frames in the frame array 30.

Next at a drill data access hole step 4020, the installation team drillsa two inch data access hole 116H in the frame array 30 as indicated inFIG. 17, again using the pilot feature 64 in the bottom row 1613 ofstructural bay members 16. In this regards, the two upper holes, at 114Hand 115H are power access holes because of their close proximity to thepower harnesses 2400HE, while the lower hole 116H is a data access holebecause of its close proximity to the data connection harnesses 2400DCCas best seen in FIG. 17. In short, a total of three holes are drilledinto the frame array 30. It should be noted that the pilot hole feature64, as best seen in FIGS. 4-8 is formed with a small starter hole. Thissmall starter hole is utilized by the installation team as they drillthese larger two inch holes in the frame array 30. This is an importantfeature of the present invention as it prevents the larger two inchdrill from slipping on the structural frame 12, which could not only bea safety hazard, but it could also increase the likelihood that theframe 12 could be damaged.

Next, the installation team at a drill centered holes step 4022, drillsone inch holes through the poster panel steel structure centered withthe two inch holes drilled in steps 4018 and 4020 respectively. Thiswill enable the wire harness installed to the face of the structuralframe array 30 to be coupled to the backside of the billboard 8 to makemechanical and electrical connections with the power and data boxesinstalled on the backside of the billboard 110 as best seen in FIG. 26.

After the holes are drilled as described-above, the installation team ata grommet installation step 4032, install two inch rubber grommets, suchas a rubber grommet 118 as best seen in FIGS. 5 and 7, in each of thethree two inch frame holes 114H, 115H and 116H respectively.

Next, at an install power/data wiring harness step 4044, theinstallation team connects in a specific sequence a set of power/datawiring harnesses, such as the wire harness 2400H. This sequence beginsat the left side of the frame array 30 in the first column indicatedgenerally at 31 in FIG. 14. Referring now to FIGS. 14, 17 and 19, theinstallation team starting with a first connection sequence indicator2401S for a first node or over mold locator 2401 in the power/datawiring harness 2400H to a first power/data node receptacle 350 in thefirst row of structural bay members 16 as best seen in FIG. 28. The teamthen continues to connect each consecutive node locator in the wireharness 2400H into the remaining locations sequentially as follows: asecond connection sequence indicator 2402S for a second node locator2402 to a second power/data node receptacle 350 in the second row ofstructural bay members 16; a third connection sequence indicator 2403Sfor a third node locator 2403 to a third power/data node 350 in thethird row of structural bay members 16; a fourth connection sequenceindicator 2404S for a fourth node locator 2404 to a fourth power/datanode 350 in the fourth row of structural bay members 16; a fifthconnection sequence indicator 2405S for a fifth node locator 2405 to afifth power/data node 350 in a fifth row of structural bay members 16.

As best seen in FIG. 28, two node receptacles 350 and 352 are disposedin the sixth row of structural bay members. Accordingly, the sequencecontinues as follows: a power slice connection sequence indicator 2400PSfor a power splice node locator 2406PS to a power slice node 352 in thesixth row of structural bay members 16; a sixth connection sequenceindicator 2406S for a sixth node locator 2406 to a sixth power/data node350 in the sixth row of structural bay members 16; a seventh connectionsequence indicator 2407S for a seventh node locator 2407 to a seventhpower/data node 350 in the seventh row of structural bay members 16; aneighth connection sequence indicator 2408S for a eighth node locator2408 to an eighth power/data node 350 in an eighth row of structural baymembers 16; a ninth connection sequence indicator 2409S for an ninthnode locator 2409 to an ninth power/data node 350 in the ninth row ofstructural bay members 16; a tenth connection sequence indicator 2410Sfor a tenth node locator 2410 to a tenth power/data node 350 in a tenthrow of structural bay members 16. This process is then repeated on acolumn by column basis from the first column 31, to a second column 32,to a third column 33, to a fourth column 34, to a fifth column 35, to asixth column 36, to a seventh column 37, to an eighth column 38, to aninth column 39, to a tenth and final column 40, until all of thestructural frames 12 in the billboard array 30 have been mechanicallyconnected to their power/data wire harnesses as best seen in FIG. 14.Although this installation sequence has been described as proceedingfrom the bottom of a column to the top of a column, it should beunderstood by those skilled in the art, that a reverse sequence could beequally utilized going from the top of a column to the bottom of acolumn.

It should be noted, that with reference to the installation step 4044,the structural frame 12 is provided with a plurality of wire routingfeatures including a data connection wire routing feature 307, a leftside data connection wiring feature 308, a power/data harness wirerouting feature 309, a right side connection wire routing feature 310and a central data connection wiring routing feature 311 as best seen inFIG. 4. Each of these wire routing features 307-311 will be describedhereinafter in greater detail. For the moment however, it will sufficeto mention that the position or location of the wire routing features307-311 within the structural frame 12 is an important feature of thepresent invention. For example the wiring features 309 are arranged in acolumn in a spaced apart manner relative to the power data receptacles350 and 352 respectively. In this regard, the power/data harness 2400Has it nodes 2400-2410 are snapped into their respective receptacles, theharness wires extended between pairs of nodes use the hook engagingunder-over-under or the over-under-over technique with each routingfeature 309 to firmly secure the power/data harness 2400H to thestructural frame 12.

Accordingly, it should be understood by those skilled in the art, thatthese features are important as they enable an installation team memberto quickly route all the preformed wire assemblies, such as the datajumper wire assembly 2400J, the data connection wire assembly 2400DC andthe power/data wire harness 2400H through the various ones of thestructural frames in the frame array 30 by an under/over/under orover/under/over hook engagement process so that these wire assemblies2400DC, 2400H, and 2400J respectively, do not separate from theirassembly structures. Most importantly however, they wire assemblies2400DC, 2400H and 2400J become seated in fixed protected locationswithin the frame array 30 and properly secured so that they arenon-interfering with the mounting of the display modules 14 and aresufficiently protected from being accidentally damaged during thedisplay module installation process. Such efficiency and safety featuresare unique and novel in the use of the retrofit kit 10. As these uniquestructures of a nodes, wire guide securing structures and paired setsand plural sets of mounting or securing hooks 42-43 respectively arerepeated in the construction of each structural frame 12, they will bedescribed in greater detail hereinafter but only with a limiteddiscussion.

Considering now in greater detail with reference to FIGS. 4 and 23, thepaired sets of mounting hooks 42, the paired set includes an upper hook42A and a lower hook 42B. The plural set of hooks 43 includes threeL-shaped hooks 43A, 43B, and 43C respectively. Each hook member, such asthe hook member 42A and 43A for example, is configured in generally anL-shape configuration to block slippage of a group of wires therefromand thus, helping to facilitate the repeated fastening steps ofunder/over/under or over/under/over for securing the preformed wireassemblies 2400DC, 2400H, and 2400J respectively to the structural frame12.

Continuing now with the installation process 1010, as best seen in FIG.22, the installation team proceeds to a verify decision step 4045, wherethe installation team verifies that all node locators have beeninstalled and are properly seated in their respective power/data nodesor receptacles 350 and 352 respectively and that the harness 2400H isproperly secured to the structural frame 12 via the wiring routingfeatures 309. This step 4045 includes routing the individual Molexconnector plugs 2400HM associated with each power/data harness 2400H totheir respective cable plug stations or daughter board cut out areasindicated generally at 330 in the structural frame 12 as best seen inFIGS. 5 and 28. When the connector 2400HM is so positioned it is allowto freely hanging in this area, where it will be available forconnection to a display module, during the display module installationprocedure (FIG. 19) that will be described hereinafter in greaterdetail. More particularly, by allowing the harness connector 2400HM tofreely hang, the process facilitates their quick and easy connection toa display module 14 when a display module 14 is ready to be seatedwithin an associated structural bay member 16. The installation teamalso route the free power wire ends of the harnesses, indicatedgenerally at 2400HE, using the wire routing features 308, 310, and 311located in the 6^(th) row of the structural frame array 30, to theirclosest power access holes 114H or 115H respectively. When the powerwires 2400HE are routed to their respective access holes 114H and 115H,the team continues routing them to the backside of the billboard 8 forconnection to their respective junction boxes as will be describedhereinafter in greater detail.

After making this verification at step 4045, the wire harnessinstallation process 4010, then proceeds to an install inter-connectingdata jumper cable step 4047. In this regard, the installation teaminterconnects the data harness wiring using a data jumper cable, such asa data jumper cable 2400J as best seen in FIG. 24A. More specifically,the installation team connects the data jumper cables 2400J in aspecific data coupling sequence that establish inter-connected datatransfer paths as best seen in FIGS. 14 and 17.

The data coupling sequence begins by a team member connecting a firstdata jumper cable 2400J between the structural frame bay members of afirst column 31 (FIG. 14) in the structural frame array 30 with thestructural frame bay members of a second column 32 in the structuralframe array 30 as best seen in FIG. 30. More specifically, a first datajumper cable connector 2400J1 of jumper cable 2400J is connected to afirst data jumper cable connector 2400DJC of the power data wiringharness 2400H in the first column 31. Then, a second data jumperconnector 2400J2 of jumper cable 2400J is connected to a first datajumper connector 2400DJC of the power data wiring harness 2400H in thesecond column 32. It should be understood by those skilled in the art,that the interconnecting cable 2400JC has a sufficient length to extendfrom one column to another column of power data wiring harnesses 2400H,such as between the first column 31 and the second column 32.

Next, the installation team connects a second jumper cable 2400J betweenthe structural frame bay members in a third column 33 in the structuralframe array 30 with the structural frame bay members of a fourth column34 in the structural frame array.

Next, the installation team connects a third jumper cable 2400J betweenthe structural frame bay members in a fifth column 35 in the structuralframe array 30 with the structural frame bay members of a sixth column36 in the structural frame array.

Next, the installation team connects a fourth jumper cable 2400J betweenthe structural frame bay members in a seventh column 37 in thestructural frame array with the structural frame bay members of a eighthcolumn 38 in the structural frame array 30.

Next, the installation team connects a fifth jumper cable 2400J betweenthe structural frame bay members in a ninth column 39 in the structuralframe array 30 with the structural frame bay members of a tenth column40 in the structural frame array 30.

After all five (5) of the data jumper cables have been installed, theinstallation team then proceeds to an interconnection step 4048 (FIG.22), where the team using data connection cables, such as the dataconnection cable 2400DC as best seen in FIG. 24B, initiates the processof installing the data connection cables, such as a data connectioncable 2400DC as best seen in FIG. 24, to the structural frame 12. Moreparticularly, these cables are routed in the bottom row 16B of thestructural bay members. In this regard, the team interconnects the firstcolumn 31 of wire harness locations 1-11 to a first data connectionconnector 2400DCJ1. Then the team interconnects the second column 32 ofwire harness locations 21 to 31 to a second data connection connector2400DCJ1. The free end plug 2400DCT and the cable wiring 2400DCC is thenrouted along the bottom row of structural bay members using the wiringrouting features 308, 310 and 311 to route the free end plug to the dataaccess hole 116H. This process is repeated for the remaining thirdthrough tenth columns 33-40 respectively. All the power and data wiringharness free ends are routed through there respective power access holes114H and 115H as well as the data access hole 116H allowing the free endto extend to the backside of the billboard 8.

Next, after the power data wire securing and routing has been completed,as best seen in FIG. 22, the installation team proceeds to an installjunction box step 4050, where the team installs a pair of lockablejunction boxes 46 and 47 respectively on the backside of the billboard 8as best seen in FIG. 26.

After completing installation of the junction boxes 46-47, theinstallation team, at an attach step 4056 attaches one hanger bracket toeach junction box with bolts and nuts, and then runs each wire harnessthrough an associated cord grip on the backside of each junction box.The team then levels the hanger bracket and secures it to the billboardsteel over the feed hole used for the wire harness. This step isrepeated for both junction boxes.

Next, the installation team proceeds to an install power data controllerenclosure step 4060, where the team installs a lockable power datacontroller enclosure or box 48 between the junction boxes 46-47, so thatconduit paths 46C and 47C respectively may be run from the junctionboxes 46 and 47 to the power enclosure box 48 as best seen in FIG. 26.The power data controller box 48 may be hoisted into place for mountingto the backside of the billboard 8, using a hand hoist or the like or inthe alternative it may simply be lifted into place by the installationteam and mounted.

Continuing, the team next at an attach step 4062, attaches one hangerbracket to on power/controller enclosure using a four bolt/nutarrangement. The team then levels the hanger bracket and secures it tothe billboard as best seen in FIG. 26 with six Tek screws into the ribsof the billboard steel. Next the team secures the two bottom attachmentpoints first than the two outer top points before removing the centerattachment from the winch or hoist.

Proceeding, the installation team at an install light sensor arrangementstep 4064, installs a light sensor box with an associated light sensordevice arrangement 50 disposed at the top portion of the billboard 8 asbest seen in FIG. 26.

Next at a measurement conduit runs step 4066, the installation teammeasures the distance between the junction boxes 46 and 47, thepower/controller enclosure 48, the main circuit breaker box (not shown),the mounting position of the light sensor junction box and to thebillboard panel where the data cable harness will be routed, whileaccounting for any bends necessary. The team then cuts conduit tubingfor each run making certain to clean the edges of the cut conduit toremove any burrs or sharp edges or points. Holes are then knocked out ineach of the enclosures in appropriate locations for a set of conduitruns 46C, 47C, 48C, 50C, 52C and 54C respectively as best seen in FIG.26.

Each piece of conduit is then installed between each section in aninstall conduit step 4068. In this regard, conduit must be secured withconduit clamps at regular intervals for the suggested layout. It shouldbe noted that all conduit connections are water proof.

Once the conduit strings 46C, 47C, 50C, 52C and 54C respectively areattached and connected, the team at a pull and connect step 4070, pullall the wire harnesses through the conduit strings or runs between thebillboard and the power/controller enclosure. Once the wires are pulledthe installation team begins to connect the wire harness into the databoard (not shown) in the power/data controller enclosure or box,indicated generally at 48 as best seen in FIG. 26.

The team then pulls all necessary power cables (not shown) through theconduit run between the power/data enclosure 48 and a universal powersource 49. A one inch hole is then punched in order to mount thewireless antenna (not shown) to the power/controller box 48. The teamthen connects the wireless antenna (not shown) to the cellular router.

A single gang weatherproof conduit box forming part of the light sensorbox arrangement 50 is then assembled to the top of the light sensorconduit 50C running to the light sensor location. The team then pullsall necessary wires from the power/controller enclosure 48 to thejunction box 47 for the light sensor arrangement 50. The wires are cutto length and terminate to the appropriately labeled terminal block inthe power/controller enclosure 48. Wire terminations to the light sensorarrangement 50 are shown in Table II:

TABLE II Red wire Terminal A Blue wire Terminal B White wire Terminal CGreen wire GroundA single gang weatherproof raised cover (not shown) is then attached tothe single gang weatherproof conduit box forming part of the lightsensor arrangement 50 using provided screws from the kit 10.

The team then pulls two 18 AWG, one 2 AWG and two 1 AWG cables throughthe conduit between the power/controller enclosure 48 and each of thejunction boxes 46 and 47. Cable is cut to length after the pull andterminated to the appropriately labeled terminal blocks. Wire harnessesare also cut to length and terminate in each junction box to itsappropriately labeled terminal block.

The team following written safety procedures makes certain that the mainpower is off at the main source. They then terminate power cables atthis power source and at power supply. At a start up step 4072, mainpower is turned on and voltages are tested at all output points asmatched in Table III:

TABLE III Output at wire harness 27 V DC Output at wire run to lightsensor  5 V DC

Finally, main power is turned off and lock out tag out is effected,which completes the wire harness installation process at an end step4080 (FIG. 22), which returns the installation process 1010 back to adetermination step 1024 (FIG. 19) where the installation team verifiesthat all the power/data harnesses 2400H, all the data jumper cables2400J and all the data connector cables 2400DC are installed andproperly connected. If any correction is needed the team returns to theinstall step 1022 and proceeds as described previously; otherwise theteam goes to a install display modules step 1026.

After verification that all the wire harnesses and power data wiring ofthe system have been installed, the installation process 1010 advancesto the install display modules step 1026 (FIG. 19). Step 1026 starts theLED tile or display module installation process indicated generally at5010 as best seen in FIG. 15.

The install display module process 5010 (FIG. 15) begins at a start step5014. From the start step 5014, the installation team proceeds to anunlatch step 5020 where the team unlatches all of the structural baylatch assemblies, such as a latch assembly 412 (FIG. 30). It iscontemplated that all latches may be unlatched at the factory where thestructural frames are assembled, so this step may be omitted.

When all the latches have been unlatched, a verification process isinitiated at a verify step 5030. Once all latches have been verified tobe unlatched, the process 5010 proceeds to an install display modulesequence step 5040. In this regard, a member of installation teamproceeds to install a first display module in the first structural bay.This process is repeated. That is, the team starts with location 1 andcontinues through location 109. Modules are not numbered and can beinstalled in any location and in any order. Therefore there is nointention of limiting the installation process to the sequence asdescribed herein. Installation of a display module 14 is simplified byusing a suitable lanyard (not shown) attached to the LED tile 14. Thelanyard is optionally used to secure the tile 14 while makingconnections with the data power connector 2400HM available at that baylocation 330. Using the lanyard to hold an LED tile 14 in place, theinstaller plugs the wire harness power data connector 2400HM into thedaughter board module data power connector 27. Then lanyard is thendisconnected as the display module 14 is now supported by the power/dataharness 2400H. Then, the installer aligns the receptacle-like alignmentfeatures 14AR and 14CAR respectively on the backside of the displaymodule 14 so they can receive the post-like alignment features 60AR and60ARC extending out in the z-axis within the structural bay member 16.When aligned, the installer simply slides the posts 60AR and 60ARC(FIGS. 4-5) into the receptacles 14AR and 14CAR (FIG. 34), as the tile14 is pushed into place in a tight-fit within the structural frame array30.

As best seen in FIGS. 4-5, 23 and 34, each display module 14 is providedwith an LED seating wall 350 which extends about the outer peripheralboundary on the backside of the LED frame 201. The wall 350 includes lowwall portions, such as a low wall portion 251 as well as high wallportions, such as a high wall portion 252. The low wall portions 251 andthe high wall portions 252 are dimensioned to be received in a tight fitin a set of Z-axis slots 712 (as best seen in FIG. 23), which slots 712are disposed in each structural bay member 16. The height of the seatingwall 250 function to define a stop, which prevents the display module 14from being further seated rearwardly within a structural bay member 16.In short when the distal end of the seating wall 250 makes contact withthe base of the receiving slots 712 (FIGS. 4-5, and 23) it provides aphysical indication to the installer that the display module 14 inprocess of being installed has been properly seated. The installer thenonly needs to proceed by latching removably the display module withinits associated structural bay member 16. In this regard, using a oneT-handled 5/32″ Hex wretch, each latch within the associated structuralbay member 16 is then turned one quarter anti-clockwise turn to securethe display module 14 within the structural frame array 30. This processis repeated until all the display modules 14 have been installed in thearray 30. The module installation process 5010, ends at an end step5050. From the end step 5050, the installation process 1010 returns tothe verification step 1028 as best seen in FIG. 19 to verify that alldisplay modules have latched into place. Once verification has beenaccomplished the team is ready to start up the billboard 110.

The Start Up Procedure

The team is now ready to engage the start up process at a start up step1030, where the team performs the following tasks: (1) they remove andclear all debris from power cabinet and Junction boxes; (2) the checkfor exposed wires; (3) they make certain that all connections aresecure; (4) they turn on switches to AC supply, power enclosure andjunction boxes in that order; (5) they refer to product user manual forfull commissioning procedure; (6) they check for initial color balance;(7) they contact the media center to upload content to be tested; andfinally (8) they verify for proper alignment of images. This process iscompleted at a verification step 1032.

Repair and Preventive Maintenance Considerations

In completing the conversion and installation process, the team performsa quick preventive maintenance process if needed. In this regard, theprocess advances to a preventive maintenance check step 1034. If nopreventive maintenance is needed the teams verifies that preventivemaintenance has been completed at a verify step 1038. If at check step1034 a determination is made that preventive maintenance needs to beperformed the process advances to a clean display module panel step 1036so the face of each display modules 16 is cleaned and so logged. Theface of the sign needs to be cleaned every six months. A log isestablished to make certain the team returns perform this cleaningprocess. Over time the LEDs will degrade and change color. When thisoccurs it will cause a visible checker board effect when replacingmodules. In this regard, when replacing modules the installation/repairteam needs to replace modules in the middle of the sign trying to swapmodules from the bottom of the display first. In this regard, replacingmodules at the bottom of the module array with newer modules is done sothe brighter modules will be less noticeable. The installation team,using a web interface can color balance the display modules 8 in orderto match colors with the older modules. When the preventive maintenancehas been completed, the team proceeds to verify that all neededpreventative maintenance step have been performed at the verificationstep 1038.

Next at a determination step 1040, the team determines whether thebillboard 110 needs any repairs. If repairs are needed the teams makesthe repairs at a repair step 1042, and verifies at a repair completedstep 1044 that all repairs have been made. If repairs are still neededthe team returns to step 1042 and continues as previously described. Ifall repairs have been completed and verified, the team has completed theinstallation of billboard 110 using the retrofit kit 10 and the processends at an end step 1046 as best seen in FIG. 26.

Conclusion

The preceding merely illustrates the principles of the invention. Itwill thus be appreciated that those skilled in the art will be able todevise various arrangements which, although not explicitly described orshown herein, embody the principles of the invention and are includedwithin its spirit and scope. Furthermore, all examples and conditionallanguage recited herein are principally intended expressly to be onlyfor pedagogical purposes and to aid the reader in understanding theprinciples of the invention and the concepts contributed by theinventors to furthering the art, and are to be construed as beingwithout limitation to such specifically recited examples and conditions.Moreover, all statements herein reciting principles, aspects, andembodiments of the invention, as well as specific examples thereof, areintended to encompass both structural and functional equivalentsthereof. Additionally, it is intended that such equivalents include bothcurrently known equivalents and equivalents developed in the future,i.e., any elements developed that perform the same function, regardlessof structure.

This description of the exemplary embodiments is intended to be read inconnection with the figures of the accompanying drawing, which are to beconsidered part of the entire written description. In the description,relative terms such as “lower,” “upper,” “horizontal,” “vertical,”“above,” “below,” “up,” “down,” “top” and “bottom” as well asderivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,”etc.) should be construed to refer to the orientation as then describedor as shown in the drawing under discussion. These relative terms arefor convenience of description and do not require that the apparatus beconstructed or operated in a particular orientation. Terms concerningattachments, coupling and the like, such as “connected” and“interconnected,” refer to a relationship wherein structures are securedor attached to one another either directly or indirectly throughintervening structures, as well as both movable or rigid attachments orrelationships, unless expressly described otherwise.

All patents, publications, scientific articles, web sites, and otherdocuments and materials referenced or mentioned herein are indicative ofthe levels of skill of those skilled in the art to which the inventionpertains, and each such referenced document and material is herebyincorporated by reference to the same extent as if it had beenincorporated by reference in its entirety individually or set forthherein in its entirety. Applicants reserve the right to physicallyincorporate into this specification any and all materials andinformation from any such patents, publications, scientific articles,web sites, electronically available information, and other referencedmaterials or documents to the extent such incorporated materials andinformation are not inconsistent with the description herein.

The written description portion of this patent includes all claims.Furthermore, all claims, including all original claims as well as allclaims from any and all priority documents, are hereby incorporated byreference in their entirety into the written description portion of thespecification, and Applicant(s) reserve the right to physicallyincorporate into the written description or any other portion of theapplication, any and all such claims. Thus, for example, under nocircumstances may the patent be interpreted as allegedly not providing awritten description for a claim on the assertion that the precisewording of the claim is not set forth in haec verba in writtendescription portion of the patent.

The claims will be interpreted according to law. However, andnotwithstanding the alleged or perceived ease or difficulty ofinterpreting any claim or portion thereof, under no circumstances mayany adjustment or amendment of a claim or any portion thereof duringprosecution of the application or applications leading to this patent beinterpreted as having forfeited any right to any and all equivalentsthereof that do not form a part of the prior art.

All of the features disclosed in this specification may be combined inany combination. Thus, unless expressly stated otherwise, each featuredisclosed is only an example of a generic series of equivalent orsimilar features.

It is to be understood that while the invention has been described inconjunction with the detailed description thereof, the foregoingdescription is intended to illustrate and not limit the scope of theinvention, which is defined by the scope of the appended claims. Thus,from the foregoing, it will be appreciated that, although specificembodiments of the invention have been described herein for the purposeof illustration, various modifications may be made without deviatingfrom the spirit and scope of the invention. Other aspects, advantages,and modifications are within the scope of the following claims and thepresent invention is not limited except as by the appended claims.

The specific methods and compositions described herein arerepresentative of preferred embodiments and are exemplary and notintended as limitations on the scope of the invention. Other objects,aspects, and embodiments will occur to those skilled in the art uponconsideration of this specification, and are encompassed within thespirit of the invention as defined by the scope of the claims. It willbe readily apparent to one skilled in the art that varying substitutionsand modifications may be made to the invention disclosed herein withoutdeparting from the scope and spirit of the invention. The inventionillustratively described herein suitably may be practiced in the absenceof any element or elements, or limitation or limitations, which is notspecifically disclosed herein as essential. Thus, for example, in eachinstance herein, in embodiments or examples of the present invention,the terms “comprising”, “including”, “containing”, etc. are to be readexpansively and without limitation. The methods and processesillustratively described herein suitably may be practiced in differingorders of steps, and that they are not necessarily restricted to theorders of steps indicated herein or in the claims.

The terms and expressions that have been employed are used as terms ofdescription and not of limitation, and there is no intent in the use ofsuch terms and expressions to exclude any equivalent of the featuresshown and described or portions thereof, but it is recognized thatvarious modifications are possible within the scope of the invention asclaimed. Thus, it will be understood that although the present inventionhas been specifically disclosed by various embodiments and/or preferredembodiments and optional features, any and all modifications andvariations of the concepts herein disclosed that may be resorted to bythose skilled in the art are considered to be within the scope of thisinvention as defined by the appended claims.

The invention has been described broadly and generically herein. Each ofthe narrower species and subgeneric groupings falling within the genericdisclosure also form part of the invention. This includes the genericdescription of the invention with a proviso or negative limitationremoving any subject matter from the genus, regardless of whether or notthe excised material is specifically recited herein.

It is also to be understood that as used herein and in the appendedclaims, the singular forms “a,” “an,” and “the” include plural referenceunless the context clearly dictates otherwise, the term “X and/or Y”means “X” or “Y” or both “X” and “Y”, and the letter “s” following anoun, designates both the plural and singular forms of that noun. Inaddition, where features or aspects of the invention are described interms of Markush groups, it is intended and those skilled in the artwill recognize, that the invention embraces and is also therebydescribed in terms of any individual member or subgroup of members ofthe Markush group.

Other embodiments are within the following claims. For example, ratherthan having as disclosed a neck-head junction with a replaceable head itis contemplated that a unitary ceramic neck-head configuration could beprovided using a reverse Morse taper head-neck to collar interconnectionallowing the unitary ceramic neck and head to be attached to a metalliccollar have a short metallic neck extending therefrom to enable thereverse Morse taper connection. Therefore, the patent may not beinterpreted to be limited to the specific examples or embodiments ormethods specifically and/or expressly disclosed herein. Under nocircumstances may the patent be interpreted to be limited by anystatement made by any Examiner or any other official or employee of thePatent and Trademark Office unless such statement is specifically andwithout qualification or reservation expressly adopted in a responsivewriting by Applicants.

Although the invention has been described in terms of exemplaryembodiments, it is not limited thereto. Rather, the appended claimsshould be construed broadly, to include other variants and embodimentsof the invention, which may be made by those skilled in the art withoutdeparting from the scope and range of equivalents of the invention.

Other modifications and implementations will occur to those skilled inthe art without departing from the spirit and the scope of the inventionas claimed. Accordingly, the description hereinabove is not intended tolimit the invention, except as indicated in the following claims.

Therefore, provided herein are a new and improved in field retrofit kitfor converting a static non electronic billboard into a dynamicelectronic billboard and methods of retrofitting a static billboard inthe field in a fast and convenient manner without the need of specialequipment. The following specific features are deemed important andunique:

Safety of Installation: HVAC power is rectified to substantially lessthan 30 VDC from the backside of the billboard 110 to the frontside ofthe billboard 110. In this regard, safety and practicality for workersto install and service the billboard 110 is of paramount importance.Higher direct current voltages or line voltages represent pending safetyhazards and may affect the required skill level of the person or personsinstalling the billboard 110. Use of the substantially less than 30 VDCpower eliminates the need for such skill labor during the installationand maintenance of the billboard 110.

Compound Frames with Specific Arrays: The new and improved billboard 110is optimized for panel form factor and assembly efficiency. In thisregard, the 4 foot by 5 foot form factor selected for the structuralframes 12 is optimized for the size of existing static panels which willbe utilized in the retrofit process. Moreover, with the use of compoundframes, such as the compound structural frames 12, the number of framesrequired to be mated with an existing panel board is greatly reduced.

Structural Foam Use: Ease of mating a structural frame 12 with anexisting static billboard 8, is achieved with the large, light-weightstructural frames, such as the structural frame 12. This is a key factorin the design criteria of the present invention; namely substantialweight reduction coupled with simple and effective molding constraints.In short, the utilization of large 4×5 foot frames is the optimal way offabrication. That is, injection molding would make molding costsprohibitive and would make the overall weight of the individual panelstoo excessive for a worker to lift and place in position without usingspecial equipment during installation. The structural foam constructionof the individual frames 12 imparts to the individual frame unusualstrength and durability effectively weatherizing the frames againststrong buffeting winds for example. The structural foam in fact is sostrong that it may be used in other applications as a structuralbuilding material or a form of heavy-duty furniture.

Bee Stops and Vent Chimney Screens: To help prevent local insects andground animals, such as bees, wasps, flies, rodents, squirrels and thelike from finding shelter between the panel boards of the billboard 8and the structural frames 12 of a converted billboard 110, each retrofitkit 10 includes a plurality of bee stops, such as a bee stop 98 that isutilized to close off the electrical pass troughs on the end of thearray structural of a structural frame 12. Pass through notches uniquelyenable the vertical routing of data connections, which at the same time,in combination with the bee stops prevent the invasion of such flyinginsects into the cooling vents 91 and electrical conduit passageways.

Easy of Operating Latches: The structural frames and bay members areconfigured with mutual mechanical datum structures coupled with centralpower and data connectors that provide for effective and easyinstallation and release of the individual LED display modules 14relative to an associated bay member 16. That is, the module latches412, which help secure each display modules within its associate baymember 16, is made ready to be acted upon through strategically placedlatch access openings 17H disposed in each display module 14.

In combination then, the retrofit kit 10 enables a static billboard 8 tobe easily and quickly converted into a dynamic billboard 110 byassembling an array of structural bays 16 upon an existing standingpanel of the static billboard 8. Each bay member 16 in this arrangement,includes a power and data connector for coupling power and data to anindividual display module 14, a strategically placed alignment features,and a uniquely operable latching feature, which operate or cooperatewith a complementary set of display module 14 features including amodule data and power connector, a module alignment feature, and amodule latching feature for enabling a display module 14 to bemechanically and electrically coupled to a bay member 14 for dynamicallydisplaying sign information. Advantageously, each display module 14 isalso provided with a weatherized sealing design which protects theelectronics and completely eliminates the need for a rigorous weatherseal which would otherwise be needed between the module 14 and the baymember 16. In this regard, the otherwise needed rigorous weather seal iseliminated by a unique and novel perforated channel member which isfilled with a potting compound in order to weatherize and seal thedisplay module 14.

Although the invention has been described in terms of exemplaryembodiments, it is not limited thereto. Rather, the appended claimsshould be construed broadly, to include other variants and embodimentsof the invention, which may be made by those skilled in the art withoutdeparting from the scope and range of equivalents of the invention.

Other modifications and implementations will occur to those skilled inthe art without departing from the spirit and the scope of the inventionas claimed. Accordingly, the description hereinabove is not intended tolimit the invention, except as indicated in the following claims.

We claim:
 1. A support for plural display modules, comprising: acompound structural frame having a back surface, a front surface, andplural peripheral edges coupling said back surface and said frontsurface for defining a plurality of structural bay members withirregularly shaped cut out areas defined by a plurality of front facesurface lateral ribs and at least one front face longitudinal rib,wherein the ribs are adiustable to comprise customized sizes rangingbetween a minimum structural bay member size and a maximum full framesize receiving and supporting therein individual and/or plural ones ofthe plural display modules respectively; wherein each individual one ofsaid plurality of structural bay members having the irregularly shapedcut out areas is provided with a front surface opening feature extendinginto a vertical channel defined in part within the back surface, saidvertical channel defining an airflow path between the back surface and apanel for a billboard, the airflow path extending through a bottomsurface of said compound structural frame through a top surface of saidcompound structural frame; and wherein each individual one of the pluraldisplay modules is provided with a set of cooling fins dimensioned to besupported within said front surface opening feature and extendingtherethrough into said vertical channel to facilitate cooling thedisplay modules.
 2. The support for plural display modules according toclaim 1, wherein said plurality of structural bay members with theirregularly shaped cut out areas are arranged in evenly spaced rows andcolumns, the rows and columns being defined by the plurality of frontface surface lateral ribs and the at least one front face surfacelongitudinal rib; and wherein said plurality of front face surfacelateral ribs and said at least one front face surface longitudinal ribdefine a plurality of cutting line guides to help facilitate cuttingsaid compound structural frame into one or more individual structuralbay members with irregularly shaped cut out areas to provide acustomized support ranging in size from the starting maximum full framesize for supporting and receiving said plural display modules to theminimum structural bay member size for supporting and receiving theindividual one of said plural display modules.
 3. The support for pluraldisplay modules according to claim, wherein said front surface isprovided with a plurality of display module mounting features tofacilitate mechanically and electrically coupling the plural displaymodules in said plurality of structural bay members.
 4. The support forplural display modules according to claim 1, wherein each individual oneof said plurality of structural bay members has a sufficient number ofcutout areas to provide a frame weight of no greater than 50 pounds forhand lifting and mounting to said front-face surface by a single personwithout the use of lifting equipment, but not such a sufficient numberof cutout areas to compromise the structural integrity of the compoundstructural frame for resisting wind load forces in excess of 100 poundsper square foot when mounted to said front-face surface while supportingthe plural display.
 5. The support for plural display modules accordingto claim 1, wherein said compound structural frame is composed ofstructural foam to help minimize frame weight for hand lifting andmounting of said compound structural frame by one person without the useof a mechanical frame lifting arrangement.
 6. The support for pluraldisplay modules according to claim 1, wherein said airflow path definedby said vertical channel is a natural convective air flow path.
 7. Thesupport for plural display modules according to claim 1, wherein saidairflow path defined by said vertical channel is a forced convective airfloe path.
 8. The support for plural display modules according to claim1, wherein a compound structural frame is provided with a plurality ofmounting features to facilitate mounting the compound structural frameto a mounting structure.
 9. The support for plural display modulesaccording to claim wherein each individual one of said plurality ofstructural bay members is provided with a plurality of irregularlyshaped cut out areas.
 10. The support for plural display modulesaccording to claim 9, wherein said plurality of structural bay membersare equally spaced apart and sized for receiving and supporting thereincorresponding individual ones of the plural display modules.